Factor analysis and numerical simulation of rock breaking efficiency of TBM deep rock mass based on orthogonal design

Abstract

This study investigates the factors affecting the rock-breaking efficiency of the TBM disc cutter in deep rock excavation, including confining pressure, penetration, cutter spacing, and revolution speed. The finite element method is employed to formulate a rock-breaking model of the rotary disc cutters and a numerical simulation is also implemented. The rock breaking effect, rock breaking volume, and rock breaking specific energy consumption under different combinations of the factors are investigated. An orthogonal test of four factors at four levels was constructed. Based on the test results and range analysis in the process of deep rock mass breaking, the order of sensitivity of each influencing factor with respect to the rock breaking specific energy for the disc cutter is cutter spacing > revolution speed > penetration > confining pressure. By constructing a numerical simulation comparison scheme, the orthogonal test results are analyzed and corroborated, and the rock breaking law and rock breaking efficiency under different influencing factors are derived. Finally, the sensitivity of different influencing factors on the rock-breaking efficiency is verified.

Keywords

deep rock mass / TBM rock breaking / rock breaking specific energy / rock breaking efficiency

References

[1] GongF-Q, SiX-F, LiX-B, et al.. Experimental investigation of strain rockburst in circular caverns under deep three-dimensional high-stress conditions [J]. Rock Mechanics and Rock Engineering, 2019, 52(5): 1459-1474

[2] MuW-Q, LiL-C, YangT-H, et al.. Numerical investigation on a grouting mechanism with slurry-rock coupling and shear displacement in a single rough fracture [J]. Bulletin of Engineering Geology and the Environment, 2019, 78(8): 6159-6177

[3] GongQ M, YinL J, WuS Y, et al.. Rock burst and slabbing failure and its influence on TBM excavation at headrace tunnels in Jinping II hydropower station [J]. Engineering Geology, 2012, 124: 98-108 in Chinese)

[4] LiX J, YangW M, WangL G, et al.. Displacement forecasting method in brittle crack surrounding rock under excavation unloading incorporating opening deformation [J]. Rock Mechanics and Rock Engineering, 2014, 47(6): 2211-2223 in Chinese)

[5] LiX-J, WangL-G, YangW-M. A numerical study of underground cavern stability by geostress characteristics [J]. Shock and Vibration, 2016, 2016: 3768453

[6] WuZ-J, JiangY-L, LiuQ-S, et al.. Investigation of the excavation damaged zone around deep TBM tunnel using a Voronoi-element based explicit numerical manifold method [J]. International Journal of Rock Mechanics and Mining Sciences, 2018, 112158-170

[7] ShiY-P, XiaY-M, TanQ, et al.. Distribution of contact loads in crushed zone between tunnel boring machine disc cutter and rock [J]. Journal of Central South University, 2019, 26(9): 2393-2403

[8] InnauratoN, OggeriC, OresteP P, et al.. Experimental and numerical studies on rock breaking with TBM tools under high stress confinement [J]. Rock Mechanics and Rock Engineering, 2006, 40(5): 429-451

[9] HongK-R, LiuH-P, ZhangW. Study on mechanism of rock fragmentation of TBM disc cutter [J]. Advanced Materials Research, 2011, 399–401: 2116-2124

[10] HanD Y, CaoP, LiuJ, et al.. An experimental study of dependence of optimum TBM cutter spacing on pre-set penetration depth in sandstone fragmentation [J]. Rock Mechanics and Rock Engineering, 2017, 50(12): 3209-3221 in Chinese)

[11] LiuJ, CaoP, HanD-Y. The influence of confining stress on optimum spacing of TBM cutters for cutting granite [J]. International Journal of Rock Mechanics and Mining Sciences, 2016, 88: 165-174

[12] GertschR, GertschL, RostamiJ. Disc cutting tests in Colorado red granite: Implications for TBM performance prediction [J]. International Journal of Rock Mechanics and Mining Sciences, 2007, 44(2): 238-246

[13] GhazvinianA, HadeiM R. Effect of discontinuity orientation and confinement on the strength of jointed anisotropic rocks [J]. International Journal of Rock Mechanics and Mining Sciences, 2012, 55: 117-124

[14] ZhangK, XiaY-M, TanQ, et al.. Numerical study on modes of breaking rock by TBM cutter under different confining pressures [J]. Chinese Journal of Geotechnical Engineering, 2010, 32(11): 1780-1787(in Chinese)

[15] GongQ-M, HeG-W, ZhaoX-B, et al.. Influence of different cutter spacings on rock fragmentation efficiency of Beishan granite by TBM [J]. Chinese Journal of Geotechnical Engineering, 2015, 37(1): 54-60(in Chinese)

[16] GongQ-M, SheQ-R, HouZ-S, et al.. Experimental study of tbm penetration in marble rock mass under high geostress [J]. Chinese Journal of Rock Mechanics and Engineering, 2010, 29(12): 2522-2532(in Chinese)

[17] ChengY-L. Numerical simulation on optimal penetration of TBM disc cutter’s rock fragmentation [J]. Journal of Central South University (Science and Technology), 2017, 48(4): 936-943(in Chinese)

[18] HongK-R, WangH-X, HanW-FSimulation study of rock breaking with hob in soft and hard uneven composite stratum [C], 2018, Pennsylvania, ECAE, 310314

[19] SuL-J, SunJ-S, LuW-B. Research on numerical simulation of rock fragmentation by TBM cutters using particle flow method [J]. Rock and Soil Mechanics, 2009, 30(9): 2823-2829(in Chinese)

[20] SunJ-S, ChenM, ChenB-G, et al.. Numerical simulation of influence factors for rock fragmentation by TBM cutters [J]. Rock and Soil Mechanics, 2011, 32(6): 1891-1897(in Chinese)

[21] HaeriH, MarjiM F. Simulating the crack propagation and cracks coalescence underneath TBM disc cutters [J]. Arab Journal of Geography, 2016, 9(2): 124(in Chinese)

[22] PengQ. Research on influence mechanism of confining pressure on rock breakage by TBM cutters [J]. Chinese Journal of Rock Mechanics and Engineering, 2014, 33S12743-2749(in Chinese)

[23] YuJ, YaoW, DuanK, et al.. Experimental study and discrete element method modeling of compression and permeability behaviors of weakly anisotropic sandstones [J]. International Journal of Rock Mechanics and Mining Sciences, 2020, 134: 104437

[24] DaiB, ShanQ-W, ChenY, et al.. Mechanical and energy dissipation characteristics of granite under cyclic impact loading [J]. Journal of Central South University, 2022, 29(1): 116-128

[25] LiuK, ChenS L. Finite element implementation of strain-hardening Drucker-Prager plasticity model with application to tunnel excavation [J]. Underground Space, 2017, 2(3): 168-174

[26] LiangZ-Z, QianX-K, ZhangY-F, et al.. Numerical simulation of dynamic fracture properties of rocks under different static stress conditions [J]. Journal of Central South University, 2022, 29(2): 624-644

[27] TanQ, ZhangX-H, XiaY-M, et al.. Numerical study on breaking rock by disc cutter at different confining pressure and joint characteristics case [J]. Journal of China Coal Society, 2014, 39(7): 1220-1228(in Chinese)

[28] ZhangZ-X, WangS-F, HuangX, et al.. Application of block theory for evaluating face stability under disc cutters loading of TBM, case study of a water-conveyance tunnel project [J]. Tunnelling and Underground Space Technology, 2019, 90249-263

[29] PengX-X, LiuQ-S, PanY-C, et al.. Study on the influence of different control modes on TBM disc cutter performance by rotary cutting tests [J]. Rock Mechanics and Rock Engineering, 2018, 51(3): 961-967

[30] FarrokhE, KimD Y. A discussion on hard rock TBM cutter wear and cutterhead intervention interval length evaluation [J]. Tunnelling and Underground Space Technology, 2018, 81: 336-357

[31] MaH-S, GongQ-M, WangJ, et al.. Linear cutting tests on effect of confining stress on rock fragmentation by TBM cutter [J]. Chinese Journal of Rock Mechanics and Engineering, 2016, 35(2): 346-355(in Chinese)

[32] HuangZ, ZhuS-Y. Sensitivity analysis of influencing factors of overburden movement based on orthogonal design [J]. Chinese Journal of Underground Space and Engineering, 2013, 9(1): 106-112(in Chinese)

[33] MuW-Q, LiL-C, YangT-H, et al.. Numerical calculation and multi-factor analysis of slurry diffusion in an inclined geological fracture [J]. Hydrogeology Journal, 2020, 28(3): 1107-1124

[34] ChangS H, ChoiS W, BaeG J, et al.. Performance prediction of TBM disc cutting on granitic rock by the linear cutting test [J]. Tunnelling and Underground Space Technology, 2006, 21(34): 271

[35] JinD-L, ShenZ-C, YuanD-J. Effect of spatial variability on disc cutters failure during TBM tunneling in hard rock [J]. Rock Mechanics and Rock Engineering, 2020, 53104609-4621 in Chinese)