Numerical investigation of slurry shield cutterhead design for clogging mitigation using a coupled computational fluid dynamics–discrete element method approach

Abstract

Cutterhead clogging remains a significant challenge in slurry shield tunneling, particularly in clay-rich strata, leading to reduced efficiency and increased operational costs. This paper presents a comparative numerical study of three common slurry shield cutterhead designs, atmospheric soft-soil cutterhead, atmospheric mix-ground cutterhead, and conventional cutterhead, using a coupled computational fluid dynamics–discrete element method (CFD–DEM) approach. The integrated CFD–DEM model allows for a detailed examination of slurry flow dynamics and granular material behavior within the cutterhead chamber. The analysis focuses on muck discharge efficiency, quantifying the volume of excavated material effectively removed, as well as particle accumulation patterns within the slurry chamber, identifying areas prone to clogging. Furthermore, the study examines cutterhead torque and thrust requirements for each design, providing a comprehensive performance assessment. Results demonstrate variations in performance across the three types, with the conventional cutterhead exhibiting the highest muck discharge rate under the tested conditions, while atmospheric-pressure designs show a higher risk of clogging due to increased particle accumulation in specific zones. This work contributes to a more informed selection and design methodology for slurry shield cutterheads, enabling engineers to optimize designs for specific soil conditions and minimize the risk of clogging in challenging geological conditions.

Graphical abstract

Keywords

slurry shield / cutterhead design / cutterhead clogging / CFD–DEM modeling

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