Field and laboratory experimental studies on hard-rock tunnel excavation based on disc cutter coupled with high-pressure waterjet

doi:10.1007/s11709-023-0947-0

Front. Struct. Civ. Eng.

2023, Vol. 17

Issue (9) : 1370-1386 https://doi.org/10.1007/s11709-023-0947-0

RESEARCH ARTICLE

Field and laboratory experimental studies on hard-rock tunnel excavation based on disc cutter coupled with high-pressure waterjet

He FEI^1,², Yiqiang LU^2,³(

), Jinliang ZHANG⁴, Xingchen LUO¹, Yimin XIA¹

¹. College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China
². China Railway Engineering Equipment Group Co., Ltd., Zhengzhou 450016, China
³. College of Civil Engineering, Tongji University, Shanghai 200092, China
⁴. Yellow River Engineering Consulting Co., Ltd., Zhengzhou 450003, China

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Abstract

The tunnel boring machine (TBM) is typically used in hard-rock tunnel excavation. Owing to the unsatisfactory adaptability of TBM to the surrounding rock, when crossing high-strength and high-wear strata, the TBM can easily cause defects, such as abnormal wear on cutters and overload damage to bearings, thus affecting the construction efficiency and cost. Therefore, high-pressure waterjet technology should be applied to assist in rock breaking for efficient TBM tunneling. In this study, the effects of water pressure, nozzle diameter, and nozzle speed on cutting are investigated via laboratory experiments of cutting hard rock using high-pressure waterjets. The penetration performance of the TBM under different water pressures is investigated via a field industrial penetration test. The results show that high-pressure waterjets are highly efficient for rock breaking and are suitable for industrial applications, as they can accommodate the advancing speed of the TBM and achieve high-efficiency rock breaking. However, during the operation of high-pressure waterjets, the ambient temperature and waterjet temperature in the tunnel increase significantly, which weakens the cooling effect of the cutterhead and decreases the construction efficiency of the TBM. Therefore, temperature control and cooling measures for high-pressure waterjets during their long-term operation must be identified. This study provides a useful reference for the design and construction of high-pressure water-jet-assisted cutterheads for breaking road headers.

Keywords tunnel boring machine hard-rock cutting free face disc cutter rock-cutting efficiency

Corresponding Author(s): Yiqiang LU

Just Accepted Date: 15 May 2023 Online First Date: 01 December 2023 Issue Date: 21 December 2023

Cite this article:

He FEI,Yiqiang LU,Jinliang ZHANG, et al. Field and laboratory experimental studies on hard-rock tunnel excavation based on disc cutter coupled with high-pressure waterjet[J]. Front. Struct. Civ. Eng., 2023, 17(9): 1370-1386.

URL:

https://academic.hep.com.cn/fsce/EN/10.1007/s11709-023-0947-0
https://academic.hep.com.cn/fsce/EN/Y2023/V17/I9/1370

Fig.1 Laboratory test equipment: (a) high-pressure waterjet cutting experimental platform; (b) mechanical rock-breaking test platform.

Tab.1 High-pressure waterjet cutting rock test scheme

Fig.2 Cutting width vs. nozzle diameter under water pressures of (a) 140 MPa and (b) 280 MPa.

Fig.3 Cutting depth vs. nozzle speed under water pressures of (a) 140 MPa and (b) 280 MPa.

Fig.4 Cracks generated via cutting using different water pressures and nozzle diameters: (a) 140 MPa water pressure and 0.53 mm nozzle diameter; (b) 140 MPa water pressure and 0.97 mm nozzle diameter; (c) 280 MPa water pressure and 0.53 mm nozzle diameter; (d) 280 MPa water pressure and 0.74 mm nozzle diameter.

Fig.5 Results of three rock-breaking methods: (a) no-kerf cutting; (b) identical cutting; (c) staggered cutting.

Fig.6 Normal and rolling forces under different experimental conditions: normal force of rock samples with different kerf depths in (a) identical cutting and (b) staggered cutting; rolling force of rock samples with different kerf depths in (c) identical cutting and (d) staggered cutting.

Fig.7 Weight of broken rock and specific energy under different experimental conditions: (a) weight of rock fragments; (b) specific energy.

Fig.8 Illustration of GB-DEM modeling process using Tyson polygon algorithm: (a) area division; (b) particle filling; (c) contact setting.

Tab.2 Micro-properties of particles and bonds

Tab.3 Mechanical properties of the synthesized rock sample for simulation and the obtained rock specimen for testing

Fig.9 Simulations and tests conducted for calibration of microscopic properties: (a) simulation of UCS test; (b) physical UCS test; (c) curves of axial stress vs. strain during UCS test and simulation; (d) simulation of BTS test; (e) physical BTS test.

Fig.10 Rock-breaking modes under kerf conditions: (a) staggered cutting; (b) identical cutting.

Fig.11 Rock-breaking performance of models with heights of 400 mm (left) and 200 mm (right).

Fig.12 Rock-breaking force of models with heights of 400 and 200 mm.

Fig.13 Rock-breaking force of models with and without pre- cut kerf.

Fig.14 Rock breaking under different cutting modes: (a) staggered cutting with kerf width of 2 mm; (b) identical cutting with kerf width of 2 mm.

Fig.15 Rock-breaking performance of models with different kerf depths: (a) 2 mm; (b) 4 mm; (c) 6 mm; (d) 8 mm; (e) 10 mm; (f) 14 mm; (g) 18 mm; (h) 22 mm; (i) 26 mm; (j) 30 mm.

Fig.16 Prototype TBM after assembly and commissioning.

Tab.4 Field experiment test scheme

Fig.17 Surrounding rock conditions around chainage D27 + 462.3?D27 + 460.5.

Fig.18 U-steel protection for high-pressure hose.

Fig.19 Cutterhead thrust force comparison: (a) disc cutter tunneling; (b) high-pressure waterjet-coupled tunneling (150 MPa); (c) high-pressure waterjet-coupled tunneling (280 MPa).

Fig.20 Penetration comparison: (a) pure disc cutter tunneling; (b) high-pressure waterjet-coupled tunneling (150 MPa); (c) high-pressure waterjet-coupled tunneling (280 MPa).

Fig.21 Cutterhead torque comparison: (a) pure disc cutter tunneling; (b) high-pressure waterjet-coupled tunneling (150 MPa); (c) high-pressure waterjet-coupled tunneling (280 MPa).

Fig.22 Relationship between water pressure and TBM penetration index.

Fig.23 Cutting effect on tunnel face with waterjet.

Tab.5 Temperature statistics of high-pressure waterjet-coupled rock-breaking tests

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