Cracks are the main cause of TBM cutter failure. As TBM cutter itself bulky, poor working conditions, the complex force function etc., the location of the cracks cannot be predicted accurately, in addition the the fatigue life of TBM cutter also do not be calculated accurately. For dealing with this problem, a method of predicting the crack position of TBM cutterhead based on crack failure regions division is proposed. The dangerous area was divided on the basis of the different stress and structure. Based on the facts, the excavation process is divided into four conditions, analyzed and summarized the stress distribution of TBM cutter in various of working conditions, combined with failure statistics and analysis of the previous crack, the cracks location can be estimated. Statistics the area which crack location belong to area based on the results of crack failure division, as a basis for analysis of crack parameters needed for TBM cutter head fatigue life. Taking the TBM cutterhead of Yin Song Jilin as an example, 10 areas has been divided according to crack-resistance, the forecast results of cracks location including the central block panel, connections between support bars and panel, the center cutter, edge hob knife welding, slag slot. calculated the regional stress amplitude combined with regions division. It's the prerequisite for calculating the fatigue life of TBM cutter.
[1] 水利部科技推广中心. 全断面岩石掘进机(TBM)[M]. 北京:石油工业出版社,2005. Promotion Center for Science&Technology Achievements of Ministry of Water Resources. Full face rock tunnel boring machine(TBM)[M]. Beijing:Petroleum Industry Press,2005.
[2] 齐梦学,王雁军,李宏亮. 敞开式掘进机全面整修技术研究与应用[J]. 现代隧道技术,2009,46(4):64-70. QI Mengxue,WANG Yangjun,LI Hongliang. Research and application of overall refit of open type TBM[J]. Modern Tunnelling Technology,2009,46(4):64-70.
[3] 李宏亮. TB880E型岩石掘进机刀盘开裂原因分析及修复方法[J]. 工程机械,2010,41(3):62-67. LI Hongliang. Troubleshooting for cutter disk cracking of model TB880 rock tunneler[J]. Construction Machinery and Equipment,2010,41(3):62-67.
[4] LING Jingxiu,SUN Wei,HUO Junzhou,et al. Study of TBM cutterhead fatigue crack propagation life based on multi-degree of freedom coupling system dynamics[J]. Computers & Industrial Engineering,2015,83(5):1-14
[5] 凌静秀,孙伟,杨晓静,等. 复杂应力状态下TBM刀盘裂纹应力强度因子分析[J]. 哈尔滨工程大学学报,2017,38(4):633-639. LING Jingxiu,SUN Wei,YANG Xiaojing,et al. Analysis of stress intensity factors for a TBM cutterhead crack incomplex stress states[J]. Journal of Harbin Engineering University,2017,38(4):633-639.
[6] HUO Junzhou,WANG Weizheng,SUN Wei,et al. The multi-stage rock fragmentation load prediction model of tunnel boring machine cutter group based on dense core theory[J]. The International Journal of Advanced Manufacturing Technology,2017,90(1-4):277-289.
[7] HUO Junzhou,HOU Nan,SUN Wei,et al. Analyses of dynamic characteristics and structure optimization of tunnel boring machine cutter system with multi-joint surface[J]. Nonlinear Dynamics,2017,87(1):237-254.
[8] HUO Junzhou,ZHU Dong,LI Guangqing,et al. Application of a small time scale fatigue crack growth model of plane stress/strain transition in life prediction of TBM cutter-head[J]. Engineering Failure Analysis,2017,71:11-30.
[9] HUO Junzhou,ZHU Dong,WANG Weizheng,et al. Theoretical crack growth prediction model for thick plate butt welding joints based on stress/strain transitions[J]. The International Journal of Advanced Manufacturing Technology,2017(3):1-16.
[10] SAMUEL S. Disc force measurements on a full-face tunnelling machine[J]. International Journal of Rock Mechanics and Mining Sciences & Geomechanics Abstracts,1984,21(2):83-96.
[11] ZHANG Z X,KOU S Q,LINDQVIST P A. In-situ measurements of cutter forces on boring machine at Äspö hard rock laboratory[J]. Rock Mechanics and Rock Engineering,2003,36(1):63-83.
[12] ROSTAMI J. Hard rock TBM cutterhead modeling for design and performance prediction[J]. Geomechanics & Tunnelling,2008,1(1):18-28.
[13] WANG Lihui,KANG Yilan,CAI Zongxi,et al. The energy method to predict disc cutter wear extent for hard rock TBMs[J]. Tunnelling and Underground Space Technology,2012,28:183-191.
[14] ZHANG Qian,QU Chuanyong,KANG Yilan,et al. Identification and optimization of energy consumption by shield tunnel machines using a combined mechanical and regression analysis[J]. Tunnelling and Underground Space Technology,2012,28:350-354.
[15] 谭青,徐孜军,夏毅敏,等. 2种切削顺序下TBM刀具破岩机理的数值研究[J]. 中南大学学报,2012,43(3):940-946. TAN Qing,XU Mujun,XIA Yimin,et al. Numerical study on mode of breaking rock by TBM cutter in two cutting orders[J]. Journal of Central South University,2012,43(3):940-946.
[16] XIA Yimin,ZHANG Xinming. Mechanical model of breaking rock and force characteristic of disc cutter[J]. Journal of Central South University,2012,19:1846-1852.
[17] 张魁,夏毅敏,朱宗铭,等. 不同地质工况条件下TBM刀具破岩模式研究[J]. 哈尔滨工程大学学报,2015,36(9):1240-1245. ZHANG Kui,XIA Yimin,ZHU Zongming,et al. Rock-breaking modes of TBM cutters under different working conditions[J]. Journal of Harbin Engineering University,2015,36(9):1240-1245.
[18] 蒲毅,刘建琴,郭伟,等. 土压平衡盾构机刀盘刀具布置方法研究[J]. 机械工程学报,2011,47(15):161-168. PU Yi,LIU Jianqin,GUO Wei,et al. Research on cutting tool layout method of earth pressure balance shield[J]. Journal of Mechanical Engineering,2011,47(15):161-168.
[19] 郭伟,胡竟,王磊,等. 基于CFD的土压平衡盾构刀盘开口分布特征研究[J]. 机械工程学报,2012,48(17):144-151. GUO Wei,HU Jing,WANG Lei,et al. Study on the opening distribution characteristics of earch pressure balance shield cutter head based on CFD[J]. Journal of Mechanical Engineering,2012,48(17):144-151.
[20] 孙伟,朱晔,凌静秀,等. 基于裂纹失效区域的分体式刀盘可靠性计算[J]. 东北大学学报,2016,37(8):1144-1148. SUN Wei,ZHU Ye,LING Jingxiu,et al. Split cutter head reliability calculation based on crack failure regions[J]. Journal of North East University,2016,37(8):1144-1148.
[21] 李舜酩. 机械疲劳与可靠性设计[M]. 北京:科学出版社,2006. LI Shunming. Mechanical fatigue and reliability design[M]. Beijing:Science Press,2006.
[22] 赵少汴. 抗疲劳设计[M]. 北京:机械工业出版社,1997. ZHAO Shaobian. The anti-fatigue design[M]. Beijing:China Machine Press,2006.
[23] YAMG K,XIA Y M,WU Y. Studies on rock-breaking of positive disc cutter and edge disc cutter[J]. Applied Mechanics & Materials,2014,508:159-164.
