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Disk cutter wear prediction of TBM considering sliding and rolling friction

Yuanjun Huang

Yuanjun Huang

School of Mechanical Engineering, Shijiazhuang Tiedao UniversityShijiazhuang City, China
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Huang, Yuanjun
, 
Rujiang Hao

Rujiang Hao

School of Mechanical Engineering, Shijiazhuang Tiedao UniversityShijiazhuang City, China
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Hao, Rujiang
, 
Jie Li

Jie Li

School of Mechanical Engineering, Shijiazhuang Tiedao UniversityShijiazhuang City, China
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Li, Jie
, 
Jingbo Guo

Jingbo Guo

School of Mechanical Engineering, Shijiazhuang Tiedao UniversityShijiazhuang City, China
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Guo, Jingbo
, 
Yankun Sun

Yankun Sun

School of Mechanical Engineering, Shijiazhuang Tiedao UniversityShijiazhuang City, China
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Sun, Yankun
 e 
Jiangran Liu

Jiangran Liu

School of Mechanical Engineering, Shijiazhuang Tiedao UniversityShijiazhuang City, China
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Liu, Jiangran
  
13 giu 2023
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Pubblicato online: 13 giu 2023
Pagine: 42 - 56
Ricevuto: 19 feb 2023
Accettato: 19 apr 2023
DOI: https://doi.org/10.2478/msp-2023-0004
Parole chiave
© 2023 Yuanjun Huang et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1.

TBM and disk cutter structure. TBM, tunnel boring machine
TBM and disk cutter structure. TBM, tunnel boring machine

Fig. 2.

Motion decomposition of disk cutter
Motion decomposition of disk cutter

Fig. 3.

Rock breaking mechanism of disk cutter
Rock breaking mechanism of disk cutter

Fig. 4.

Force diagram of disk cutter
Force diagram of disk cutter

Fig. 5.

Disk cutter with normal wear dismantled on site
Disk cutter with normal wear dismantled on site

Fig. 6.

Geological profile of the tunnel
Geological profile of the tunnel

Fig. 7.

Introduction of cutter head and cutter
Introduction of cutter head and cutter

Fig. 8.

Disk cutter wear values were measured on site
Disk cutter wear values were measured on site

Fig. 9.

Actual wear data and installation radius of disk cutter
Actual wear data and installation radius of disk cutter

Fig. 10.

Normally worn disk cutter ring and test piece
Normally worn disk cutter ring and test piece

Fig. 11.

Hardness test of disk cutter ring
Hardness test of disk cutter ring

Fig. 12.

Impact test of disk cutter ring
Impact test of disk cutter ring

Fig. 13.

SEM and OES test of disk cutter ring material. (A) SEM test process. (B) OES test process. OES, optical emission spectroscopy; SEM, scanning electron microscope
SEM and OES test of disk cutter ring material. (A) SEM test process. (B) OES test process. OES, optical emission spectroscopy; SEM, scanning electron microscope

Fig. 14.

Metallurgical structure of disk cutter ring material
Metallurgical structure of disk cutter ring material

Fig. 15.

Rock samples
Rock samples

Fig. 16.

Geological conditions along the line. (A) Stratum classification. (B) Rock mass strength distribution
Geological conditions along the line. (A) Stratum classification. (B) Rock mass strength distribution

Fig. 17.

Contact force diagram
Contact force diagram

Fig. 18.

Model for rock breaking with disk cutter
Model for rock breaking with disk cutter

Fig. 19.

Simulation results derived post-processing
Simulation results derived post-processing

Fig. 20.

Comparison between the predicted wear values and the actual wear data
Comparison between the predicted wear values and the actual wear data

Fig. 21.

Comparison between actual wear data and predicted wear values under different penetration
Comparison between actual wear data and predicted wear values under different penetration

Structure parameters of disk cutter ring

Outer diameter of cutter ring (mm) Width of cutter ring (mm) Blade width (mm) Cutting edge angle Fillet radius (mm)
483 89 19 24° 32

Comparison of vertical forces from simulation and theoretical models

Condition Average vertical force of simulation model (kN) Vertical forces calculated by CSM model (kN) Absolute value relative error
Condition 1 201.3 205.9 2.2%
Condition 2 149.4 156.3 4.3%
Condition 3 116.2 122.3 4.9%
Condition 4 77.8 84.1 7.5%

Rock attributes of each working condition

Condition Compressive strength (MPa) Tensile strength (MPa) Density (g/mm3)
Condition 1 120 11.2 2.9 × 10−3
Condition 2 90 8.7 2.7 × 10−3
Condition 3 70 6.9 2.6 × 10−3
Condition 4 50 4.4 2.5 × 10−3

Chemical composition of disk cutter ring material

Chemical element C Cr Mn Si Mo V S P
Chemical composition of cutter ring (%) 0.49 5.15 0.47 1.07 1.46 0.98 0.009 0.012
Chemical composition of 4Cr5MoSiV1 (%) 0.32– 0.45 4.75– 5.50 0.20– 0.50 0.80– 1.20 1.10– 1.75 0.80– 1.20 ≤ 0.03 ≤ 0.03

A 19-inch disk cutter with basic parameters

Material name of cutter ring Outer diameter of cutter ring (mm) HRC Width of the cutter edge (mm) Cutter spacing (mm)
4Cr5MoSiV1 483 50–54 19 80
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