Research on rock-breaking effect of TBM hob and application of new type cutter
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摘要: TBM滚刀磨损是影响TBM掘进效率和施工成本的重要因素，不同刀刃刃形的破岩效率和磨损均会有所不同。本文对楔形弧刃滚刀的破岩机理进行了分析，建立了滚刀法向切削力计算模型，分析了滚刀刀刃角对法向切削力的影响；继而设计了3种不同刀间距、3种不同刃形滚刀，并进行了室内滚刀破岩试验。试验结果表明：刀间距15 mm为合理刀间距；尖刃滚刀最易磨损，齿刃比弧刃滚刀破岩效果好，破岩效率相对较高且耐磨损。结合工程现场实际情况，研发了一种新型齿刃楔形刀具，并应用到工程现场TBM斜井掘进。应用情况表明：新型齿刃楔形刀具比两种常规刀具的磨损量减少20 %，刀具寿命有所提高。新型齿刃楔形刀具的研发和成功应用，解决了斜井TBM掘进刀具的较大磨损和频繁更换问题，为TBM长距离斜井掘进提供了技术支持，缩短了掘进工期，节约了施工成本。Abstract: TBM hob wear is an important factor that affects the TBM tunneling efficiency and construction cost.Different blade types differ in rock breaking efficiency and wear.By analyzing the rock-breaking mechanism of the arc blade wedged hob, this study established the calculation model of hob normal cutting, and analyzed the influence of hob edge angle on normal cutting force.This study then designed three kinds of hobs with different cutter spacing and three types of hobs with different blade for rock breaking tests in laboratory.Results show that the reasonable cutter spacing is 15mm, sharp blade is prone to be worn, the tooth-like blade, which has higher rock breaking efficiency and wear resistance, is better than arc blade.Combined with the actual situation of the project site, a new hob with wedge-shaped blade is developed, which are applied to inclined shaft TBM tunneling at engineering site.Results show that the wear rate of the new wedge-shaped hob is 20 % less than that of the conventional ones, and the service life of former is longer than that of latter.Under the same geological conditions, new wedge-shaped hob can reduce the number of hobs consumption and improve efficiency of tunnelling.The development and application of the new type successfully solved the problems of hob wear and frequent replacement of hobs in the TBM inclined shaft excavation.It can provide technical support for TBM long distance inclined shaft driving, which not only shortened the construction period, but also saved the construction cost.
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Key words:
- rock breaking /
- wedge-shaped hob /
- hob wear /
- inclined shaft TBM tunneling
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图 1 楔形弧刃滚刀破岩形式[23]
F1—滚刀刃端挤压岩石产生的作用力；F2、F3—刀刃两侧面在推进过程中对两侧岩石的作用力
Figure 1. Rock failure by arc blade wedged hob
图 2 滚刀对岩石剪切破坏块受力分析
OA—滚刀与岩石的接触面；OB—剪切破坏面；AB—岩石表面；θ—滚刀刀刃角的1/2；α—滚刀与岩石的摩擦角；ψ—剪切作用下破坏面与水平面的夹角，其值与岩石的破碎角有关
Figure 2. Force analysis of the shear failure block by hob
图 6 滚刀楔形弧刃端与剪切破碎块接触面积法向方向投影
Figure 6. Vertical direction projection on the area of arc blade wedged hob contacting with shear failure block
图 11 刀间距10 mm、15 mm、20 mm完成一次破岩工作面
Figure 11. Rock breaking face in hob spacing 10 mm, 15 mm, 20 mm
图 13 不同刀刃形岩石破碎区线激光3D扫描图
Figure 13. Laser scanning map of rock fragmentation zone in different cutting edges
表 1 现场某区间段岩石力学参数
Table 1. Mechanical parameters of in-situ rock
密度/(kg·m-3) 抗压强度/MPa 抗拉强度/MPa 弹性模量/GPa 黏聚力/MPa 泊松比 内摩擦角φb/(°) 2 550 20 1.4 18 5.8 0.22 37 
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表 2 不同刀刃线激光3D扫描测量岩石破碎区相关参数
Table 2. Parameters of rock crushing area measured by laser scanning with different cutting edges
刀刃形 破碎位置 1/4区域 2/4区域 3/4区域 4/4区域 3D扫描计算值 尖刃 贯入深度/mm 6.02 6.05 5.98 5.97 6.01 破碎面积/mm2 28 083.28 28 206.29 26 614.73 26 353.80 109 258.11 破碎体积/mm3 138 384.64 114 038.53 79 671.64 66 359.87 398 454.69 齿刃 贯入深度/mm 7.96 8.08 8.06 7.95 8.01 破碎面积/mm2 26 515.11 27 261.89 28 936.07 22 296.18 105 009.24 破碎体积/mm3 90 842.75 148 923.72 136 914.77 60 500.62 437 181.84 弧刃 贯入深度/mm 8.02 7.99 8.06 8.03 8.03 破碎面积/mm2 26 512.64 26 490.84 26 268.14 25 578.76 104 850.39 破碎体积/mm3 99 613.48 77 646.25 102 378.37 98 282.80 377 920.89
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表 3 不同刀刃形破岩比能耗
Table 3. Rock breaking energy consumption of different blade types
刀刃形 贯入度/mm 刀盘平均法向力/kN 刀盘平均切向力/kN 破岩体积/cm3 比能耗/(MJ·m-3) 尖刃 6 4.2 1.37 398.46 68.69 弧刃 8 7.41 2.78 377.92 121.00 齿刃 8 6.69 2.51 437.18 94.43
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表 4 3类刀具主要参数
Table 4. Main parameters of three kinds of cutters
刀具类别 直径/mm 刀刃宽度/mm 屈服强度/MPa 刀具编号(正面刀) A刀 457 30 1 815 14，19，22，23，28，29，34，35 B刀 432 19 1 494 15，18，20，25，26，31，32，37 C刀 432 19 1 494 13，16，17，21，24，27，30，33，36
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表 5 区间单位滚动路径磨损值
Table 5. Wear value per unit cutting distance
A刀 B刀 C刀 编号 磨损量/mm 刀具位置 单位磨损值/(mm·m-1) 编号 磨损量/mm 刀具位置 单位磨损值/(mm·m-1) 编号 磨损量/mm 刀具位置 单位磨损值/(mm·m-1) 14号 74 1 240 6.0 15号 102 1 330 7.7 13号 96 1 150 8.3 19号 91 1 690 5.4 18号 120 1 600 7.5 16号 116 1 420 8.2 22号 117 1 960 6.0 20号 134 1 780 7.5 17号 118 1 510 7.8 23号 112 2 050 5.5 25号 139 2 230 6.2 21号 144 1 870 7.7 28号 115 2 500 4.6 26号 141 2 320 6.1 24号 147 2 140 6.9 29号 116 2 590 4.5 31号 160 2 770 5.8 27号 147 2 410 6.1 34号 131 3 040 4.3 32号 161 2 860 5.6 30号 155 2 680 5.8 35号 123 3 130 3.9 37号 180 3 300 5.5 33号 168 2 950 5.7 36号 170 3 220 5.3 平均 109.9 5.0 平均 142.1 6.5 平均 140.1 6.9
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