Prediction and analysis of slurry shield TBM disc cutter wear and its application in cutter change time

Shen, Xiang; Chen, Xiangsheng; Fu, Yanbin; Cao, Chengyong; Yuan, Dajun; Li, Xuhui; Ye, Xiao

doi:10.1016/j.wear.2022.204314

Cited by 20 publications

(6 citation statements)

References 23 publications

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“…Based on a series of CAI tests, the relationship between the wear coefficients and CAI was deduced. They also proposed a disc tool wear prediction model based on the abrasive mode l [2]. A new method was proposed for calculating the CERCHAR index based on the mass loss of the pin tip with respect to the dimensions of the pin-tip plane.…”

Section: Introductionmentioning

confidence: 99%

“…However, in the existing cutter wear prediction model used in actual engineering applications, there are still some problems (1) Due to the complexity of the stress situation when the cutter breaks, researchers have not clearly defined the complex stress state of the disc cutter breaking. (2) The existing research has mainly focused on the plastic removal mechanism of abrasive wear without considering the brittle removal mechanism and fatigue damage. Additionally, the impact of cutter wear on the calculation of the wear amount was not considered.…”

Section: Introductionmentioning

confidence: 99%

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Force and wear prediction model of disc cutter under compression shear failure mode based on dense core–cavity expansion theory (U-713)

Su,

Guan,

Deng

et al. 2024

IOP Conf. Ser.: Earth Environ. Sci.

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Calculating disc cutter wear and predicting wear life are long-standing issues affecting the efficiency and cost of tunnel boring machines (TBMs). During the TBM excavation process, the wear of the disc cutter is a comprehensive outcome of the interaction between the tool and rock. Studying the mechanisms of tool rock breaking and wear can assist in developing a more precise model for predicting cutter wear. Therefore, based on the rock-breaking and wear mechanisms of a cutter, this study developed a model for predicting the cutter wear rate and life. The model is based on the theory of dense core–cavity expansion combined with the motion state of a cutter. First, the TBM excavation process and rock-breaking mechanism of a cutter were analyzed in detail. A cutting force model under the compression shear failure mode based on the dense core–cavity expansion theory was established. Based on the force model, a prediction model for the wear rate and life of the disc cutter was established, considering the working characteristics and wear mechanism. Furthermore, the impact of penetration on the prediction model was investigated. In addition, to demonstrate the practicality of the method, this study conducted a comprehensive examination using engineering examples. The results showed that the average difference in the cutter average wear rate using the developed model was less than 3% compared with the actual engineering result. In addition, the average difference in the wear life rate was less than 5%. Finally, the developed prediction method was compared with other models. The wear rate fitting accuracy was improved by 4.91–10.85% and the wear life fitting accuracy was improved by 5.11–12.19% by the developed method. This improvement confirms the reasonableness and reliability of the method. This method can estimate the wear rate and lifespan of a cutter more accurately and reliably than other methods, providing a practical tool to TBM engineers to make informed decisions and optimize tool replacement programs.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Force and wear prediction model of disc cutter under compression shear failure mode based on dense core–cavity expansion theory (U-713)

Su,

Guan,

Deng

et al. 2024

IOP Conf. Ser.: Earth Environ. Sci.

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“…Only a few scholars considered disk cutter wear from the perspective of energy during TBM construction. They analyzed the wear mechanism of cutters according to the law of energy conservation: Shen et al [14] established a prediction model for disk cutter wear considering energy conversion and uneven thrust distribution and proposed a method to determine the energy conversion rate and thrust distribution coefficient, which was verified by the project. Song [15] suggested the superiority of the energy principle in the study of TBMs and the layout design of disk cutters.…”

Section: Introductionmentioning

confidence: 99%

Disk cutter wear prediction of TBM considering sliding and rolling friction

Huang

Hao

et al. 2023

Materials Science-Poland

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Considering the serious wear of disk cutters in tunnel project and the low prediction accuracy of existing methods, a new method for wear prediction of disk cutters from an energy perspective was proposed. Based on contact mechanics, the rock breaking process of cutters was analyzed, and the combined action of sliding and rolling friction was considered. Furthermore, the wear prediction model of disk cutters was established, which realized the predicted wear of disk cutters under different geological conditions throughout the construction line. In addition, considering the influence of penetration on the wear prediction model, the predicted wear values under different penetrations were obtained, and their average values were taken as the predicted wear values of disk cutters considering penetration. Finally, the predicted wear values were compared with the actual wear value of disk cutters. The results showed that the average relative error between the predicted wear value of disk cutters considering sliding and rolling friction and the actual wear data was 12.8%. The average relative error between the predicted value of wear considering only sliding friction and the actual value of disk cutters is 18.3%. The average relative error between the predicted value of disk cutter wear considering penetration and the actual wear data was 12.2%, which proved the feasibility and accuracy of the prediction model. Meanwhile, it is more accurate than the model only considering sliding friction. The research results provided a scientific theoretical basis for the design of a tool change scheme in tunnel construction.

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“…During the shield tunneling process, the shield machine head rotates and drives the disc cutters to cut up the rock. However, the disc cutters are prone to wear and tear during tunneling, and replacing them is an expensive and time-consuming activity that affects the speed and efficiency of shield tunneling [ 2 , 3 ]. The existing disc cutter replacement method is manually done and needs assisted mechanical tools.…”

Section: Introductionmentioning

confidence: 99%

Line-Features-Based Pose Estimation Method for the Disc Cutter Holder of Shield Machine

Xie

Zhu

Zhang

et al. 2023

Sensors

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To achieve automatic disc cutter replacement of shield machines, measuring the accurate pose of the disc cutter holder by machine vision is crucial. However, under polluted and restricted illumination conditions, achieving pose estimation by vision is a great challenge. This paper proposes a line-features-based pose estimation method for the disc cutter holder of the shield machine by using a monocular camera. For the blurring effect of rounded corners on the image edge, a rounded edge model is established to obtain edge points that better match the 3D model of the workpiece. To obtain the edge search box corresponding to each edge, a contour separation method based on an adaptive threshold region growing method is proposed. By preprocesses on the edge points of each edge, the efficiency and the accuracy of RANSAC linear fitting are improved. The experimental result shows that the proposed pose estimation method is highly reliable and can meet the measurement accuracy requirements in practical engineering applications.

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Prediction and analysis of slurry shield TBM disc cutter wear and its application in cutter change time

Cited by 20 publications

References 23 publications

Force and wear prediction model of disc cutter under compression shear failure mode based on dense core–cavity expansion theory (U-713)

Force and wear prediction model of disc cutter under compression shear failure mode based on dense core–cavity expansion theory (U-713)

Disk cutter wear prediction of TBM considering sliding and rolling friction

Line-Features-Based Pose Estimation Method for the Disc Cutter Holder of Shield Machine

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