Analysis of load and adaptability of disc cutters during shield tunneling in soft–hard varied strata

doi:10.1007/s11709-023-0946-1

Front. Struct. Civ. Eng.

2023, Vol. 17

Issue (4) : 533-545 https://doi.org/10.1007/s11709-023-0946-1

RESEARCH ARTICLE

Analysis of load and adaptability of disc cutters during shield tunneling in soft–hard varied strata

Fengwei YANG^1,², Weilin SU^1,³(

), Yi YANG³, Zhiguo CAO^1,²

¹. Yellow River Engineering Consulting Co., Ltd., Zhengzhou 450003, China
². Key Laboratory of Water Management and Water Security for Yellow River Basin, Ministry of Water Resources, Zhengzhou 450003, China
³. Key Laboratory of Urban Underground Engineering of Ministry of Education, Beijing Jiaotong University, Beijing 100044, China

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Abstract

The disc cutters of shield machines exhibit unsatisfactory adaptability and performance during the soft–hard varied strata tunneling process. To analyze the rotation state, cutting performance, and adaptability of disc cutters during shield tunneling in soft–hard varied strata, the Holmquist Johnson Cook and Federal Highway Administration constitutive models are introduced to numerically simulate the failure process of materials on the excavation face and to calculate the load of disc cutters. Additionally, the parameters of the models are modified based on laboratory disc cutter excavation test results. The results of numerical calculation can reflect the load level and the behavior of the disc cutters during operation. The tangential loads of the disc cutters during the cutting of four typical soft-strata excavation face models are numerically calculated, thus providing reference values for the starting torque of the disc cutters. A greater penetration is suggested for soft-strata tunneling to allow the disc cutters to rotate smoothly and continuously as well as to guarantee a better cutting effect. The disc cutters in the center of the cutterhead should be specified with a lower starting torque to prevent uneven wear, rotation stagnation, cutterhead clogging, and other adverse phenomena.

Keywords shield tunneling disc cutter load laboratory excavation test numerical calculation soft–hard varied strata

Corresponding Author(s): Weilin SU

About author:

^* These authors contributed equally to this work.

Just Accepted Date: 24 February 2023 Online First Date: 19 May 2023 Issue Date: 25 June 2023

Cite this article:

Fengwei YANG,Weilin SU,Yi YANG, et al. Analysis of load and adaptability of disc cutters during shield tunneling in soft–hard varied strata[J]. Front. Struct. Civ. Eng., 2023, 17(4): 533-545.

URL:

https://academic.hep.com.cn/fsce/EN/10.1007/s11709-023-0946-1
https://academic.hep.com.cn/fsce/EN/Y2023/V17/I4/533

model type	parameter type	parameter assignment	value
HJC model	basic parameters	ρ (kg/m³)	2110
		G (MPa)	$8.75 × 103$
		T (MPa)	1.62
		f_c (MPa)	24.45
	strength parameters	A	0.272
		B	1.50
		N	0.87
		SF_MAX	20
	state equation parameters	p_l (MPa)	$1.78 × 103$
		μ_l	0.16
		p_c (MPa)	8.15
		μ_c	$6.99 × 10 ? 4$
		K₁ (GPa)	9.23
		K₂ (GPa)	141.24
		K₃ (GPa)	136.50
	strain rate effect parameters	C	0.012
	strain rate effect parameters	ESP0	1.0
	damage parameters	D₁	0.04
		D₂	1.0
		EF_MIN	0.01
FHWA model	basic parameters	ρ (kg/m³)	1408.7
		ρ_W (kg/m³)	1.00
		G_s	1.80
	elastic parameters	K (MPa)	11.03
		G (MPa)	5.09
		$D 1$	0
	yield parameters	c (MPa)	2.21 × 10^?2
		$φ$ (° )	24.4
		a	2.37 × 10^?3
	excess pore water pressure parameters	$ω$	0.033
	excess pore water pressure parameters	$D 2$	0
	strain hardening and softening parameters	AN	0
		D_int	5.0 × 10^?5
		$φ m a x$ (° )	40
	strain rate effect parameters	V_n	0
	strain rate effect parameters	γ	0

Tab.1 Parameter assignments of the HJC and FHWA constitutive models

Fig.1 Excavation test platform.

Fig.2 Excavation face model in soft–hard varied strata.

Tab.2 Material ratio and consumption per cubic meter

Tab.3 Uniaxial compressive strength of different materials

Fig.3 Finite element model of the excavation face and disc cutters.

Fig.4 Residual strain distribution obtained from numerical simulations: (a) soil cutting numerical simulation based on the FHWA model; (b) concrete cutting numerical simulation based on the HJC model.

Fig.5 Comparison and correction of numerical calculation results based on the HJC model.

Fig.6 Flowchart of the constitutive model parameter modification.

Fig.7 Comparison and correction of numerical calculation results based on the FHWA model.

Fig.8 Equivalent stress dynamic distribution in soft-stratum cutting: (a) H = 1.0 mm; (b) H = 3.0 mm; (c) H = 6.0 mm.

Fig.9 Disc cutter load vs. time at different cutting depths (based on the HJC model).

Fig.10 Disc cutter load vs. time at different cutterhead rotation speeds (based on the HJC model).

Fig.11 Disc cutter load vs. time at different cutting depths (based on the FHWA model).

Fig.12 Disc cutter load vs. time at different cutterhead rotation speeds (based on the FHWA model).

Fig.13 Starting torque measurement of the disc cutter.

soil type	FHWA model parameter values
soil type	ρ (kg/m³)	K (MPa)	G (MPa)	c (kPa)	$φ$ (° )	$φ m a x$ (° )	AN	D_int	V_n	γ
ordinary soil	1408	9.8	2.3	17.41	25.2	40	0	5.0 × 10^?5	1.1	0.10
hard soil	1514	51.8	22.1	13.35	27.6	42	0	5.0 × 10^?5	1.2	0.10
sandy gravel hard soil	1920	125.4	51.0	25.90	30.7	45	0	5.0 × 10^?5	1.2	0.10
strongly weathered sandy conglomerate	2050	208.5	112.6	42.00	34.7	45	0	5.0 × 10^?5	1.2	0.15

Tab.4 Parameter values of the FHWA constitutive model for different materials

Fig.14 Mean and variance of disc cutter load vs. cutting depth.

Fig.15 Mean and variance of disc cutter load vs. rotation speed of cutterhead.

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