Layout design for disc cutters based on analysis of TBM cutter-head structure

Abstract

Studies to date have failed to consider gage disc cutters’ variable cutting depth and the constraints of cutter-head welds, and have ignored the coupling mechanism between the profile of the full-face rock tunnel-boring machine (TBM) cutter-head and the assembled radius layout of the disc cutters. To solve these problems, an adaptive design method for studying cutter layout was proposed. Taking the bearing stress of the outermost gage disc cutter as an index, the profile of the cutter-head was determined. Using a genetic algorithm and based on the principles of equal life and equal wear, the assembled radii of the cutters were optimally designed. Boundary conditions of non-interference between the cutters, manholes, muck buckets and welding lines were given when a star layout pattern was used on cutters. The cutter-head comprehensive evaluation model was established by adopting relative optimization improvement degree of evaluation indices to achieve dimensional consistency. Exemplifying the MB264-311-8030 mm tape TBM cutter-head, the calculations show that compared with the original layout scheme, among the 51 disc cutters, the largest gap of the cutters’ assembled radiuses is only 25.8 mm, which is 0.64% of the cutter-head’s radius and is negligible. The cutter-head’s unbalanced radial force decreases by 62.41%, the overturning moment decreases by 33.22%, and the cutter group’s centroid shift increases by only 18.48%. Each index is better than or approximately equal to the original cutter-head layout scheme, and the equivalent stress and deformation are both smaller; these results fully verify the feasibility and effectiveness of the method.

Keywords

split type cutter-head / disc cutters’ layout / genetic algorithm / equal life / equal wear / star layout pattern

References

[1] ZhangPengDesign and research on cutter layout and the structural parameters of the cutterhead optimization for TBM [D], 2009, Dalian, School of Mechanical Engineering, Dalian University of Technology

[2] ZhouJ-leiResearch on the cutter-head design and analysis of full face TBM [D]. Beijing: School of Energy, 2011

[3] ZhangZ-h, QiaoY-li. Research on the layout of TBM disc cutter [J]. Engineering Mechanics, 2011, 28(5): 172-177

[4] HuoJ-z, SunW, ChenJing. Optimal disc cutters plane layout design of the full-face rock tunnel boring machine based on a multi-objective genetic algorithm [J]. Journal of Mechanical Science and Technology, 2010, 24(2): 521-528

[5] YuS-qiangThe coupling layout design method of cutters group and supporting structure of full face rock TBM [D], 2013, Dalian, School of Mechanical Engineering, Dalian University of Technology

[6] Research on the cutter layout based on the load analysis [J], 2016, 49(1

[7] GUO Wei, SUN Hong-yan, LIU Jian-qin, SONG Li-wei, SUN Bin. Optimal layout design for disc cutters’ assembled radiuses based on tbm cutter-head profile [EB/OL]. http://www.cnki.net/kcms/detail/12.1127.N.20151222.1343.0 02.html, 2015–12-22.

[8] ShenBinResearch on optimal layout of TBM gage disc cutters combination [D], 2014, Changsha, College of Mechanical and Electrical Engineering, Central South University

[9] QiaoY-liCutter layout design of full-face rock tunnel boring machine [D], 2009, Beijing, School of Energy Power and Mechanical Engineering, North China Electric Power University

[10] ZhangZ-h, YeD-hai. The model of the disc cutter’s broken-rock and the calculation of its side force [J]. Journal of Basic Science and Engineering, 2011, 285): 172-177

[11] ZhangH-mei. Study on numerical simulations of performance of tunnel boring machines (TBM) [J]. Tunnel Construction, 2007, 26: 1-7

[12] HuoJ, SunX, LiG. Multi-degree-of-freedom coupling dynamic characteristic of TBM disc cutter under shock excitation [J]. Journal of Central South University, 2015, 22: 3326-3337

[13] ZhangZ-h, JiC-ming. Analytic solution and its usage of arc length of rock breakage point of disc edge on full face rock tunnel boring machine [J]. Journal of Basic Science and Engineering, 2009, 17(2): 265-273

[14] ShuBiaoStudy the wear volume calculation and wear performance of TBM cutter based on abrasive wear [D], 2014, Changsha, College of Mechanical and Electrical Engineering, Central South University

[15] HuoJ-z, SunW, ChenJ, ZhangXu. Disc cutters plane layout design of the full-face rock tunnel boring machine (TBM) based on different layout patterns [J]. Computers & Industrial Engineering, 2011, 61(4): 1209-1225

[16] SunW, HuoJ-z, ChenJ, LiZ, ZhangX, GuoL, ZhaoH-f, ZhaoYu. Disc cutters’ layout design of the full-face rock tunnel boring machine (TBM) using a cooperative coevolutionary algorithm [J]. Journal of Mechanical Science and Technology, 2011, 25(2): 415-427

[17] GengQ, WeiZ-y, DuJ, LuB-heng. Cutters’ layout optimization method of the full-face rock tunnel boring machine based on grey relational analysis [J]. Journal of Mechanical Engineering, 2014, 50(21): 45-53

[18] ZhangWeiStudy of cutter layout design of full-face rock tunnel boring machine [D], 2009, Dalian, School of Mechanical Engineering, Dalian University of Technology