刃形对硬岩地层中TBM滚刀磨损行为的影响研究

全断面隧道掘进机(TBM)是用于长大隧道建设的关键装备，在公路铁路、引水输水等国家重大战略工程中发挥着重要作用. 盘形滚刀位于TBM最前端，是执行破岩掘进的关键零部件. 冲击重载和缺少润滑等恶劣工况条件导致滚刀在面对硬岩地层时磨损速率极高，频繁更换刀具对隧道建设的工期、成本和安全性造成严重负面影响. 对滚刀磨损机理的深入研究是建立长寿命高性能滚刀设计方法的必经之路. 滚刀截面形状以及表面结构是刀-岩接触行为的决定性因素之一，而接触行为对滚刀磨损存在直接影响，但机理机制尚不十分清楚. 本文中使用高强度花岗岩开展滚刀磨损试验，针对工程实际中最常用的平顶与圆顶滚刀，研究不同刃形滚刀在磨损过程中切削力、质量损失和表面形貌演变的规律，并结合有限元数值仿真，揭示滚刀刃形通过改变刀-岩接触状态而影响其磨损行为的机理. 结果表明，在通过相同距离时平顶滚刀直径变化量小，即达到磨损极限时行进总距离更长、耐磨性更好. 圆顶滚刀接触应力集中效应明显，容易发生局部磨损，使圆顶滚刀半径变化更大；但在相同刀盘推力下，圆顶滚刀侵入岩石的深度大于平顶滚刀，在破岩效率方面具有潜在优势. 本研究对工程实际中滚刀选型与设计具有重要指导意义.

Full Face Tunnel Boring Machine (TBM) is a key equipment for the construction of long and large tunnels, playing an important role in major national strategic projects such as highway and railway construction, water diversion and conveyance projects. Disc cutters are located at the foremost end of the TBM and are the core components responsible for rock breaking and tunneling. Harsh operating conditions including impact heavy loads and insufficient lubrication lead to extremely high wear rates of disc cutters when encountering hard rock formations, and frequent tool changes impose severe negative impacts on the construction period, cost and safety of tunnel projects. In-depth research on the wear mechanism of disc cutters is a prerequisite for establishing design methods for long-service-life and high-performance disc cutters. The cross-sectional shape and surface structure of disc cutters are among the decisive factors affecting cutter-rock contact behavior, which directly influences the wear of disc cutters, yet the underlying mechanism remains not fully clarified. In this paper, wear tests of disc cutters are conducted using high-strength granite. Focusing on the two most commonly used disc cutters in practical engineering: flat-top and dome-top disc cutters, this study investigates the evolution rules of cutting forces, mass loss and surface morphology of cutters with different edge shapes during the wear process. Combined with finite element numerical simulation, the mechanism that the cutter edge shape affects its wear behavior by altering the cutter-rock contact state is revealed. The results show that flat-top disc cutters have a smaller diameter change when traveling the same distance, meaning they require a longer total travel distance to reach the wear limit and exhibit better wear resistance. Dome-top disc cutters present obvious contact stress concentration effects and are prone to local wear, leading to a larger radius change; however, under the same cutterhead thrust, dome-top disc cutters have a greater penetration depth into rock compared with flat-top ones, showing potential advantages in rock breaking efficiency. This study has important guiding significance for the selection and design of disc cutters in practical engineering.

搜集汇总

背景与挑战

背景概述

该数据集研究了全断面隧道掘进机(TBM)盘形滚刀在硬岩地层中的磨损行为，重点关注不同刃形（平顶与圆顶）滚刀的磨损机理。通过实验和有限元仿真，揭示了刃形对刀-岩接触状态及磨损行为的影响，为滚刀选型与设计提供了重要指导。