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.
摘要
目前,滚刀布局设计研究中存在许多不足,如边滚刀变切深的特性,刀盘焊缝的约束条件,刀 盘剖面轮廓与滚刀极径布置的耦合机制问题等均未被考虑和重视。为解决这些问题,笔者提出了一种 基于刀盘剖面轮廓和焊缝约束条件的刀具布局的适应性设计方法。以最外侧刀具的轴承受力为评价准 则,给出平面刀盘的剖面轮廓设计方法;采用GA 算法,基于等寿命原则和等磨损原则,对边刀的倾 斜角进行了优化设计;给出了对滚刀进行星型布置时,滚刀与滚刀、人孔、出渣槽以及焊缝之间不干 涉的边界条件;采用各指标在邻近两次布局中的相对优化提高度进行量纲的一致性处理,建立了刀盘 的综合评价模型,完成刀具的周向布置。以MB264-311-8030 mm 型TBM 刀盘为案例,计算结果表明, 与原始滚刀的布局相比,51 把滚刀中,极径的最大差距仅有25.8 mm,相对于刀盘的半径大小为0.64%, 极小;刀盘的径向不平衡力减少了62.41%,倾覆力矩减少了33.22%,质心偏斜量仅增加了18.48%, 各指标都优于或近似等于原始刀盘布局结果;刀盘的应力和变形均小于原始刀盘,有效地验证了模型 的可行性。
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
ZHANG Peng. Design and research on cutter layout and the structural parameters of the cutterhead optimization for TBM [D]. Dalian: School of Mechanical Engineering, Dalian University of Technology, 2009. (in Chinese)
ZHOU Ji-lei. Research on the cutter-head design and analysis of full face TBM [D]. Beijing: School of Energy, Power and Mechanical Engineering, North China Electric Power University, 2011. (in Chinese)
ZHANG Zhao-huang, QIAO Yong-li. Research on the layout of TBM disc cutter [J]. Engineering Mechanics, 2011, 28(5): 172–177. (in Chinese)
HUO Jun-zhou, SUN Wei, CHEN Jing. 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.
YU Shi-qiang. The coupling layout design method of cutters group and supporting structure of full face rock TBM [D]. Dalian: School of Mechanical Engineering, Dalian University of Technology, 2013. (in Chinese)
LIU Jian-qin, QIN De-chang, GUO Wei. Research on the cutter layout based on the load analysis [J]. Journal of Tianjin University: Science and Technology, 2016, 49(1): The page number is uncertain. (in Chinese)
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.
SHEN Bin. Research on optimal layout of TBM gage disc cutters combination [D]. Changsha: College of Mechanical and Electrical Engineering, Central South University, 2014. (in Chinese)
QIAO Yong-li. Cutter layout design of full-face rock tunnel boring machine [D]. Beijing: School of Energy Power and Mechanical Engineering, North China Electric Power University, 2009. (in Chinese)
ZHANG Zhao-huang, YE Ding-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, 28(5): 172–177. (in Chinese)
ZHANG Hou-mei. Study on numerical simulations of performance of tunnel boring machines (TBM) [J]. Tunnel Construction, 2007, 26(Sup. 2): 1–7. (in Chinese)
HUO J, SUN X, LI G, et al. Multi-degree-of-freedom coupling dynamic characteristic of TBM disc cutter under shock excitation [J]. Journal of Central South University, 2015, 22: 3326–3337.
ZHANG Zhao-huang, JI Chang-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. (in Chinese)
SHU Biao. Study the wear volume calculation and wear performance of TBM cutter based on abrasive wear [D]. Changsha: College of Mechanical and Electrical Engineering, Central South University, 2014. (in Chinese)
HUO Jun-zhou, SUN Wei, CHEN Jing, ZHANG Xu. 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.
SUN Wei, HUO Jun-zhou, CHEN Jing, LI Zhen, ZHANG Xu, GUO Li, ZHAO Hai-feng, ZHAO Yu. 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.
GENG Qi, WEI Zheng-ying, DU Jun, LU Bing-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.
ZHANG Wei. Study of cutter layout design of full-face rock tunnel boring machine [D]. Dalian: School of Mechanical Engineering, Dalian University of Technology, 2009. (in Chinese)
Author information
Authors and Affiliations
Corresponding author
Additional information
Foundation item: Projects(51275339, 51575379, 51675374) supported by the National Natural Science Foundation of China; Project(2013CB035402) supported by the National Hi-tech Research and Development Program of China
Rights and permissions
About this article
Cite this article
Sun, Hy., Guo, W., Liu, Jq. et al. Layout design for disc cutters based on analysis of TBM cutter-head structure. J. Cent. South Univ. 25, 812–830 (2018). https://doi.org/10.1007/s11771-018-3786-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11771-018-3786-8