滚刀的磨损消耗是全断面岩石隧道掘进机（Tunnel boring machines，TBM）掘进成本的重要组成部分。针对于此，基于中国秦岭和挪威Røssåga硬岩隧道的实际工程数据，使用能量分析的方法对滚刀磨损进行了分析研究。提出了滚刀刃单位磨损功和等效磨损函数，通过分析刀盘上不同区域滚刀的运动、受力和磨损机制，建立了基于各刀位滚刀破岩载荷、滚刀安装参数和TBM掘进参数的滚刀刃单位磨损功计算公式。通过求解8.8 m和7.23 m直径TBM的等效磨损函数，并计算相应的滚刀刃单位磨损功，对比分析了不同刀盘、不同地质条件和不同刀盘区域的滚刀磨损，发现：等效磨损函数与滚刀寿命系数（CLI）成反比，等效磨损函数的对称轴位置取决于滚刀布局，对称轴位置的滚刀破岩和磨损状态最理想。揭示了刀盘内侧和外侧区域滚刀高磨损率的原因，提出了增大刀盘内侧滚刀间距、增大30°～40°倾角的边滚刀数目的滚刀布局建议。
The consumption of disc cutters on full-face rock tunnel boring machines (TBMs) accounts for a large percentage of the tunnel excavation cost. Based on the engineering data from Qinling rock tunnel in China and Røssåga rock tunnel in Norway, the wear mechanism of disc cutters has been studied with an energy approach. The unit friction work of cutter rings and an equavilent wear function are proposed and analyzed. The calculation formula of the cutter ring unit friction work is established according to the rock breaking loads, cutter position parameters and TBM boring parameters by analyzing the movement, load and wear mechanism of disc cutters on different cutter positions. Based on the solvement of the equivalent wear function and the calculation of the cutter ring unit friction work for the 8.8 m and 7.23 m diameter TBMs respectively, the wear of cutters on different cutterhead zones for TBMs boring through tunnel sections with different geology parameters is analyzed. It is found that the equivalent wear function is inversely proportional to the cutter life index (CLI). The symmetry axis of the equavilent wear function is determined by the disc cutter layout. The rock breaking and cutter wear status of the cutters around the symmetry axis is the best. By revealing the reasons for high wear rate of the cutters on inner and outer cutterhead zones, suggestions for cutter layout design are given, e.g. increasing the spacing of cutters in inner cutterhead zones, add more gage cutters with the tilt angle between 30° to 40°.
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