Journal of Jilin University(Engineering and Technology Edition) ›› 2026, Vol. 56 ›› Issue (8): 2162-2176.doi: 10.13229/j.cnki.jdxbgxb.20250042

Previous Articles    

Life prediction of TBM disc cutters considering dense core effect and compression⁃shear failure mode

Chao WANG(),Jin-feng ZOU(),Liang LI,Dan SHU   

  1. School of Civil Engineering，Central South University，Changsha 410075，China
  • Received:2025-01-12 Online:2026-08-01 Published:2026-09-02
  • Contact: Jin-feng ZOU E-mail:wangchao214801069@yeah.net;zoujinfeng_csu@163.com

RICH HTML

 0   

PDF (PC)

12

Abstract:

In order to accurately predict the service life of the hob in the rock-breaking process of Tunnel Boring Machine（TBM） to improve the boring efficiency and determine the time of changing the hob， this study analyzed the rock-breaking mechanism of the disk hob and established the calculation model of the normal force of rock-breaking hob of TBM based on the shear and tensile failure mechanism. The Rabinowicz abrasive wear model was improved based on the dense core effect to establish the wear rate and life prediction model of TBM disc cutters considering dense core effect and compression-shear failure mode. The engineering applicability of the prediction model proposed in this study was verified by the comparing the prediction results with the existing theoretical model calculation results， numerical simulation results and on-site monitoring results. The results show that the predicted values of this model are closer to the measured values in the engineering field. Compared with the existing theoretical model， the average prediction accuracies of cutter wear rate and cutter life are improved by 9.1% and 11.7% respectively， which effectively demonstrates the necessity of comprehensively considering the dense core effect and compression-shear failure mode in the calculation of TBM cutters breaking rock. The cutter wear rate and life index can be used as reliable indexes for evaluating the cutter wear characteristics during the rock breaking process of TBM， which can provide theoretical guidance for the design and timing of cutters change program in TBM tunnel and other similar projects.

Key words: tunnel boring machine, rock-breaking, service life, disc cutter, dense core effect, compression-shear failure mode

CLC Number: 

  • U455

Fig.1

Rock breaking diagram of TBM disc cutter"

Fig.2

Micro element dφ mechanical analysis model of hob invading rock"

Fig.3

Schematic diagram of stress distribution in hob section"

Fig.4

Shear damage surface and strength envelope based on Mohr?Coulomb strength criterion"

Fig.5

Simplified schematic diagram of rock breakingmechanics of TBM cutter in rock shear failuremode"

Fig.6

Schematic diagram of TBM hob invading rock in rock compression failure mode"

Fig.7

Simplified model of Rabinowicz abrasive wear"

Fig.8

Improved simplified model of Rabinowicz abrasive wear based on dense core effect"

Table 1

Technical parameters of composite EPB shield machine"

参数数值参数数值
整机功率/kW1 726.22中心滚刀数量/把8
刀盘转速/（r·min-1）2.2正面滚刀数量/把31
扭矩/（kN·m）2 500边缘滚刀数量/把14
盾构推力/kN12 000滚刀直径/mm432
掘进速度/（mm·min-1）15刀刃宽度/mm17
刀盘开口率/%32滚刀刃角/（°）20
刀盘压力/MPa8.0刀圈硬度/HRC55
刀盘额定功率/kW945推进油缸总推进力/t4 086
最大贯入度 /mm≥10开挖直径/mm6 420

Fig.9

Distribution area division of rolling cutters"

Fig.10

Geological profile of shield tunnels in interval from Qingshanhu West Station to Shangshagou Station"

Table 2

Statistics of physical and mechanical parame- ters of rocks and soils in each stratum"

地层天然重度/（kN·m-3）黏聚力/kPa内摩擦角/（°）压缩模量/MPa泊松比
素填土17.8218--
粉质黏土17.63526300.32
中砂18.2036420.22
砾砂22.5042560.18
微风化花岗岩26.518 30042.51000.25

Fig.11

Layout of holes required for tool wear monitoring"

Fig.12

Statistics of accumulated wear of roller cutters in 210~552 rings of right tunnel measured on site"

Fig.13

Structure and dimensions of TBM disc cutter"

Table 3

Cutter ring material of TBM disc hob"

材料模型密度/（kg·m-3）弹性模量/GPa泊松比
线弹性模型7 5002100.3

Table 4

Statistical table of material parameters of rock sample model"

岩层

密度/

（kg·m-3）

抗压

强度/

MPa

抗拉

强度/

MPa

弹性

模量/GPa

泊松比完整性系数Kv滚压系数Kn
微风化花岗岩2 650857.1522.50.250.520.65

Fig.14

Numerical model of TBM disc cutter breaking rock"

Fig.15

Wear rate variation curve of TBM disk cutters considering only compression-shear failure mode"

Fig.16

Wear rate variation curve of TBM disk cutters considering dense core effect and compression- shear failure mode"

Fig.17

Validation curve of disk cutter life prediction model for TBM rock breaking process consid-ering only compression-shear failure mode"

Fig.18

Validation curve of disk cutter life prediction model in TBM rock breaking process considering dense nucleation effect and compression-shear failure mode"

Fig.19

Statistics of variation of life prediction error of disk cutters during TBM breaking rock"

Fig.20

Wear rate variation curves of TBM disc cutters calculated by different models"

Fig.21

Service life variation curves of TBM disc cutters calculated by different models"

[1] 孙健, 陈亮, 马洪素, 等. 完整极硬岩TBM施工辅助破岩方法研究现状及展望[J]. 世界核地质科学, 2024, 41(1): 141-163.
Sun Jian, Chen Liang, Ma Hong-su, et al. Research status and prospect of assisting rock breaking methods for TBM tunnelling in extremely hard rocks[J]. World Nuclear Geoscience, 2024, 41(1): 141-163.
[2] 张蒙祺, 勾斌, 邓雨, 等. 新型TBM螺旋槽滚刀破岩性能及接触行为研究[J]. 机械工程学报, 2023, 59(5): 259-270.
Zhang Meng-qi, Gou Bin, Deng Yu, et al. Cutting performance and contact behavior of a novel TBM cutter with surface spiral grooves[J]. Journal of Mechanical Engineering, 2023, 59(5): 259-270.
[3] 翟淑芳, 杜红坤, 岳奇超, 等. 基于特征粒径的盘形滚刀破岩最优贯入度分析[J]. 现代隧道技术, 2023, 60(4): 147-152, 162.
Zhai Shu-fang, Du Hong-kun, Yue Qi-chao, et al. Analysis of the optimal penetration of disc cutter in rock breaking based on characteristic particle size[J]. Modern Tunnelling Technology, 2023, 60(4): 147-152, 162.
[4] 李国龙, 李彪, 蒋林, 等. 基于HHT和IPSO算法优化RBF神经网络的滚刀磨损状态识别方法[J]. 吉林大学学报:工学版, 2020, 50(6): 1998-2009.
Li Guo-long, Li Biao, Jiang Lin, et al. Hob wear recognition method based on HHT and IPSO-RBF neural network[J]. Journal of Jilin University(Engineering and Technology Edition), 2020, 50(6): 1998-2009.
[5] 曹久磊, 俞缙, 张竹清, 等. 考虑破岩模式的TBM滚刀破岩力计算模型[J]. 煤炭学报, 2023, 48(8): 3300-3311.
Cao Jiu-lei, Yu Jin, Zhang Zhu-qing, et al. Force calculation model of TBM disc cutter based on rock breaking mode[J]. Journal of China Coal Society, 2023, 48(8): 3300-3311.
[6] Hu X K, Du C L, Liu S Y, et al. Three-dimensional numerical simulation of rock breaking by the tipped hob cutter based on explicit finite element[J]. IEEE Access, 2019, 7: 86054-86063.
[7] Li X, Wu J Q, Huo P. Prediction model for the teeth hob cutter of tunnel boring machines in high-content quartzite strata[J]. KSCE Journal of Civil Engineering, 2023, 27(1): 371-383.
[8] She L, Li Y L, Wang C, et al. Prediction of TBM disc cutter wear based on field parameters regression analysis[J]. Geomechanics and Geoengineering, 2023, 35(6): 647-663.
[9] 王超, 乔世范, 刘红中. TBM破岩过程的滚刀受力计算模型研究[J]. 工程力学, 2021, 38(10): 54-63.
Wang Chao, Qiao Shi-fan, Liu Hong-zhong. Research on force calculation model of hob in TBM rock breaking progress[J]. Engineering Mechanics, 2021, 38(10): 54-63.
[10] 张斌荣, 管会生, 谭孝锋, 等. 基于MATLAB/Simulink的TBM边滚刀动力学模型及振动分析[J]. 隧道建设:中英文, 2020, 40(6): 833-839.
Zhang Bin-rong, Guan Hui-sheng, Tan Xiao-feng, et al. Dynamic model and vibration analysis of TBM edge-cutter based on MATLAB/Simulink[J]. Tunnel Construction, 2020, 40(6): 833-839.
[11] Rostami J. Development of a force estimation model for rock fragmentation with disc cutters through theoretical modeling and physical measurement of crushed zone pressure[D]. Golden:Colorado School of Mines, 1997.
[12] Bruland A. Hard rock tunnel boring[D]. Trondheim:Norwegian University of Science and Technology, 1998.
[13] Wang L H, Kang Y L, Zhao X J, et al. Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis[J]. Tunnelling and Underground Space Technology, 2015, 50(1): 324-333.
[14] Yang Y D, Hong K R, Sun Z C, et al. The derivation and validation of TBM disc cutter wear prediction model[J]. Geotechnical and Geological Engineering, 2018, 36(6): 3391-3398.
[15] Su W L, Li X G, Jin D L, et al. Analysis and prediction of TBM disc cutter wear when tunneling in hard rock strata: a case study of a metro tunnel excavation in Shenzhen, China[J]. Wear, 2020, 446-447(4): No.203190.
[16] 佘磊, 张社荣, 和孙文, 等. 基于密实核理论的TBM盘形滚刀磨损预测模型研究[J]. 岩土工程学报, 2022, 44(5): 970-978.
She Lei, Zhang She-rong, He Sun-wen, et al. Prediction model for TBM disc cutter wear based on dense core theory[J]. Chinese Journal of Geotechnical Engineering, 2022, 44(5): 970-978.
[17] Ke C C, Chen C S, Ku C Y, et al. Modeling crack propagation path of anisotropic rocks using boundary element method[J]. International Journal for Numerical and Analytical Methods in Geomechanics, 2009, 33(9): 1227-1253.
[18] Zhang Z H, Aqeel M, Li C, et al. Theoretical prediction of wear of disc cutters in tunnel boring machine and its application[J]. Journal of Rock Mechanics and Geotechnical Engineering, 2019, 11(1): 111-120.
[19] 赵坚, 李海波. 莫尔-库仑和霍克-布朗强度准则用于评估脆性岩石动态强度的适用性[J]. 岩石力学与工程学报, 2003, 22(2): 171-176.
Zhao Jian, Li Hai-bo. Estimating the dynamic strength of rock using Mohr-Coulomb and Hoek-Brown criteria[J]. Chinese Journal of Rock Mechanics and Engineering, 2003, 22(2): 171-176.
[20] Rabinowicz E. Friction and Wear of Materials[M]. New York: John Wiley & Sons, 1995.
[21] 赵海鸣, 舒标, 夏毅敏, 等. 基于磨料磨损的TBM滚刀磨损预测研究[J]. 铁道科学与工程学报, 2014, 11(4): 152-158.
Zhao Hai-ming, Shu Biao, Xia Yi-min, et al. Study of wear prediction for TBM cutter based on abrasive wear model[J]. Journal of Railway Science and Engineering, 2014, 11(8): 152-158.
[22] Bruland A. Hard rock tunnel boring[D]. Trondheim:Norwegian University of Science and Technology, 1998.
[23] Ma L, Low S R, Fink J. Effects of steel and tungsten carbide ball indenters on Rockwell hardness measurements[J]. Journal of Testing and Evaluation, 2006, 34(3): 187-199.
[24] 石振明, 刘鎏, 管圣功, 等. 盾构机前舱设备可视化检测系统研究与应用[J]. 公路交通科技, 2019, 36(1): 109-116.
Shi Zhen-ming, Liu Liu, Guan Sheng-gong, et al. Study on visualized detector of shield machine forecabin equipment and its application[J]. Journal of Highway and Transportation Research and Development, 2019, 36(1): 109-116.
[25] 杨延栋, 陈馈, 李凤远, 等. 盘形滚刀磨损预测模型[J]. 煤炭学报, 2015, 40(6): 1290-1296.
Yang Yan-dong, Chen Kui, Li Feng-yuan, et al. Wear prediction model of disc cutter[J]. Journal of China Coal Society, 2015, 40(6): 1290-1296.
[26] 刘杰, 邓立营, 倪志华, 等. TBM滚刀磨损量及其使用寿命预测方法[J]. 机械设计, 2024, 41(10): 59-66.
Liu Jie, Deng Li-ying, Ni Zhi-hua, et al. Method of predicting TBM disc cutter's wear and service life[J]. Journal of Machine Design, 2024, 41(10): 59-66.
[1] CUI Xianghong， JIANG Qichuan， WANG Shuqi， LI Junyi. Application and Improvement of Service Life of Hotforging [J]. 吉林大学学报(工学版), 2005, 35(06): 567-0572.
Viewed
Full text


Abstract

Cited
  Shared   
  Discussed   
No Suggested Reading articles found!
Copyright © Journal of Jilin University(Engineering and Technology Edition), All Rights Reserved.
Tel: +86-431-85095297　Fax: +86-431-85094074　E-mail: xbgxb@jlu.edu.cn
Powered by Beijing Magtech Co. Ltd