Cutter Load Characteristics and Effect of Cutter Profile in Multi-Cutter Rock-Breaking Condition
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摘要:
为保障全断面隧道掘进机（TBM，Tunnel Boring Machines）在复杂地形下安全、高效运行，需明确多滚刀协同破岩时滚刀的载荷特性，并分析各种刃形滚刀在不同地层中的性能表现. 为此，建立多滚刀协同破岩的颗粒流离散元数值模型，分析平顶、圆顶2种刃形滚刀在不同岩石强度、刀盘转速下的载荷特性，并通过多刀破岩试验对数值分析主要结果加以验证. 结果表明：在给定贯入度条件下，圆顶滚刀所需法向总推力较平顶滚刀低23%～50%，其破岩体积与比能亦低10%～20%；不同安装半径滚刀所受载荷有所差异，最内、最外侧滚刀仅与相邻单侧滚刀形成协同破岩作用，其切削力较邻刀高约30%，故滚刀切削力的均值与标准差随安装半径增大呈两端高、中间低的“W”形分布；2种刃形滚刀法向力的均值与标准差均呈正相关，但在相同法向推力水平下，平顶滚刀的法向力标准差较圆顶滚刀低37%～50%，表明圆顶滚刀可能引起更为剧烈的振动；此外，随刀盘转速的提高，2种滚刀的切削力均相应增大，其中平顶滚刀对转速变化更为敏感.
Abstract:To ensure the safe and efficient operation of full-face tunnel boring machines (TBMs) in complex terrains, it is essential to clarify the load characteristics of cutters in the multi-cutter collaborative rock-breaking condition and to analyze the performance of cutter profiles in different geological strata. Therefore, a numerical discrete element model based on the particle-flow method for the multi-cutter collaborative rock-breaking condition was established. The load characteristics of flat-tipped and circle-tipped cutters under varying rock strength and rotational speeds of cutterheads were investigated. Additionally, multi-cutter rock-breaking experiments were conducted to verify the accuracy of the numerical analysis results. The findings indicate that under a given penetration depth, the circle-tipped cutter exhibits a normal total thrust that is 23%−50% lower than that of the flat-tipped cutter, along with a reduction in rock-breaking volume and specific energy by 10%−20%. The load of cutters at different installation radii varies. The innermost and outermost cutters only collaborate in rock breaking with adjacent single-sided cutters, so the cutting force is approximately 30% higher than that of the adjacent cutter. Consequently, the mean and the standard deviation of cutting forces show a “W”-shaped distribution, with higher values at both ends and lower values in the middle as the installation radius increases. The mean and standard deviation of the normal forces for both cutter profiles are positively correlated. However, at the same level of normal thrust, the flat-tipped cutter exhibits a 37%−50% lower standard deviation of normal force, which means the circle-tipped cutter may lead to more severe vibrations. Additionally, the cutting forces for both types of cutters increase with an elevation in the rotational speed of the cutterhead. The flat-tipped cutter exhibits greater sensitivity to variations in the rotational speed.
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Key words:
- tunnel boring machine /
- cutter /
- cutter profile /
- cutting force /
- discrete element
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图 1 多刀破岩的颗粒流离散元-有限差分混合模型
Figure 1. Particle flow-based discrete element and finite difference hybrid model in multi-cutter rock-breaking condition
图 2 岩石力学性能测试（花岗岩为例）
Figure 2. Tests of rock’s mechanical properties （with granite as an example）
图 5 多刀破岩模型的滚刀布局及编号
Figure 5. Layout and number of cutters in multi-cutter rock-breaking model
图 10 各滚刀的法向力均值及标准差
Figure 10. Mean and standard deviation of normal forces of each cutter
图 13 不同刀盘转速下滚刀的总法向力变化历程
Figure 13. Variation of total normal forces of cutters with different rotational speeds of cutterheads
图 14 不同刀盘转速下滚刀的破岩表现
Figure 14. Rock-breaking performance of cutters with different rotational speeds of cutterheads
图 15 不同刀盘转速下滚刀的法向力均值及标准差
Figure 15. Mean and standard deviation of normal force of cutters with different rotational speeds of cutterheads
表 1 模拟与试验结果的对比
Table 1. Comparison between simulation and experiment results
岩石 项目 单轴抗压强度/MPa 单轴抗拉强度/MPa 杨氏模量/GPa 泊松比 大理岩 实验 69.8 69.8 129.6 130.0 仿真 6.95 8.1 7.9 19.2 花岗岩 实验 42.0 42.2 57.6 57.1 仿真 0.168 0.165 0.263 0.256 
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表 2 离散元模型细观参数
Table 2. Microscopic parameters of discrete element model
项目 细观参数 大理岩 花岗岩 颗粒属性 最小颗粒直径/mm 3.5 3.5 最大颗粒直径/mm 5.6 5.6 表观密度/（kg•m−3） 2654 2565 局部阻尼系数 0.7 0.7 线性组 有效模量/GPa 19.2 34.0 摩擦系数 0.4 0.5 刚度比 1.8 5.2 平行黏结组 黏结激活间隙/mm 0.35 0.35 半径乘子 1.0 1.0 有效模量/GPa 19.2 34.0 刚度比 1.8 5.2 弯矩贡献系数 1.0 1.0 抗拉强度均值/MPa 8.2 31.9 抗拉强度标准差/MPa 0.82 3.19 内聚力均值/MPa 41.0 159.5 内聚力标准差/MPa 4.1 16.0
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