240 research outputs found

    Discrete/finite element modelling of rock cutting with a TBM disc cutter

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    The final publication is available at Springer via http://dx.doi.org/10.1007/s00603-016-1133-7This paper presents advanced computer simulation of rock cutting process typical for excavation works in civil engineering. Theoretical formulation of the hybrid discrete/finite element model has been presented. The discrete and finite element methods have been used in different subdomains of a rock sample according to expected material behaviour, the part which is fractured and damaged during cutting is discretized with the discrete elements while the other part is treated as a continuous body and it is modelled using the finite element method. In this way, an optimum model is created, enabling a proper representation of the physical phenomena during cutting and efficient numerical computation. The model has been applied to simulation of the laboratory test of rock cutting with a single TBM (tunnel boring machine) disc cutter. The micromechanical parameters have been determined using the dimensionless relationships between micro- and macroscopic parameters. A number of numerical simulations of the LCM test in the unrelieved and relieved cutting modes have been performed. Numerical results have been compared with available data from in-situ measurements in a real TBM as well as with the theoretical predictions showing quite a good agreement. The numerical model has provided a new insight into the cutting mechanism enabling us to investigate the stress and pressure distribution at the tool–rock interaction. Sensitivity analysis of rock cutting performed for different parameters including disc geometry, cutting velocity, disc penetration and spacing has shown that the presented numerical model is a suitable tool for the design and optimization of rock cutting process.Peer ReviewedPostprint (published version

    Design optimization of TBM disc cutters for different geological conditions

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    A novel optimization methodology for the disc cutter designs of tunnel boring machines (TBM) was presented. To fully understand the characteristics and performance of TBM cutters, a comprehensive list of performance parameters were investigated, including maximum equivalent stress and strain, specific energy and wear life which were closely related to the cutting forces and profile geometry of the cutter rings. A systematic method was employed to evaluate an overall performance index by incorporating objectives at all possible geological conditions. The Multi-objective & Multi-geologic Conditions Optimization (MMCO) program was then developed, which combined the updating of finite element model, system evaluation, finite element solving, post-processing and optimization algorithm. Finally, the MMCO was used to optimize the TBM cutters used in a TBM tunnel project in China. The results show that the optimization significantly improves the working performances of the cutters under all geological conditions considered

    Study on the optimum penetration depth by two TBM cutters under different cutter spacings

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    This paper investigates the optimum penetration depth and the synergistic effect of TBM (Tunnel Boring Machine) rock breaking under the different cutter spacings. Indentation tests, using two TBM cutters, were conducted on sandstone specimens based on an improved uniaxial testing. Afterwards, morphological measurement was performed to analyze the change of the groove volume, using a surface profilometer. Based on the evaluations of typical chips and cracks propagation, the fragmentation modes of the rock between two cutters under different penetration depths were proposed. In addition, the TBM rock breaking efficiency was studied. As the increase of the penetration depth, when the cutter spacing was constant, the results show that: (1) The rock fragmentation modes gradually changed from shear failure and shear-tensile failure to tensile failure. (2) Though penetration energy gradually increased, the groove volumes also increased, thus, the TBM rock breaking efficiency rises. (3) Specific energy decreased first and then gradually increased. It indicates that the optimum penetration depth was existent for different preset penetration depths. With the increase in cutter spacing, the optimum penetration depth also rised. According to the derivation and verification of the analytical formula, the internal relationship between the penetration depth and the fracture toughness was obtained, which was in line with the linear relationship between penetration depth and penetration energy. From a microscopic point of view, the sharp increase of penetration energy with increase of penetration depth can be explained

    Cutting Characteristics and Layout of Pre-cutting Machine Cutter

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    The pre-cutting machine is becoming valued due to its ability to effectively prevent surface settlement and reduce vibration in tunnel construction. To obtain the cutting characteristics and layout of pre-cutting machine cutter, the cutting tests by the pre-cutting machine cutter are conducted and the cutting laws are also studied. The research results show that the cutting force rather than normal force and side force is responsible for the rock breaking. With the increase of the cutting depth and cutting spacing, the cutting forces increase generally. But for the little value of cutting spacing, the cutting force can not increase continuously when the cutting depth increase to a relatively large value. Furthermore, for a given cutting depth, the cutting force will keep at an approximate constant rather than continuous increase with the increase of the cutting spacing when the cutting spacing increases to a relatively large value. The specific energy decreases nonlinearly with the increase of cutting depth and the decrease of specific energy is not significant when the cutting depth is more than 12 mm. Moreover, there exists an optimal cutting spacing for a given cutting depth. To maintain a desirable cutting efficiency, the ratio of cutting spacing to cutting depth should be controlled between 1 and 2. Finally, the layout plan of the pre-cutting machine cutter is proposed based on the research results and is applied in the actual manufacturing of the pre-cutting machine

    UČINCI SADRŽAJA VODE I VELIČINE ZRNA NA ZAČEPLJENJE I ABRAZIVNOST SITNOZRNATOG TLA KOD MEHANIZIRANOG OTKOPVANJA

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    Clogging during excavation is one of the common problems in mechanized excavation. Among the influential factors in clogging of the cutter head, we can mention the percentage of fine soil particles (under 200 mesh sieve), soil moisture, and soil type. In this study, to investigate the mechanism of tunnel excavation in the laboratory, a tunnel excavation machine laboratory simulator was designed and built. The features of this device are its horizontal operation, the low rotation speed of the cutter head, continuous contact of the pins with fresh soil during the test, and the continuous injection of additives with a specific injection pressure during the test. The effect of the percentage of fine-grained, soil moisture and the foam injection ratio (FIR) on clogging, energy consumed, and the average wear of cutting tools was studied. The results showed that with an increase in the percentage of fine soil particles from 90 to 100%, the clogging of cutting tools increased by 50%. Also, with an increase of soil moisture from a dry state to moisture content of 5%, clogging of the cutter head is insignificant, and after that, with an increase of moisture from 10 to 25%, clogging is increased by 178%, and the amount of energy consumed in each test is increased by 84%. In addition, by increasing the foam injection ratio from 40 to 60%, clogging decreased by 81% on average, and the wear of cutting tools decreased by 62% on average.Začepljenje tijekom iskopa je jedan od uobičajenih problema kod mehaniziranog otkopavanja. Među utjecajnim čimbenicima u začepljenju rezne glave možemo spomenuti postotak sitnih čestica tla (čestice koje prolaze kroz otvore sita 200 mesh), vlažnost i tip tla. U ovoj studiji, kako bi se istražio mehanizam iskopa tunela u laboratoriju, projektiran je i izgrađen laboratorijski simulator stroja za iskop tunela. Karakteristike ovog uređaja su horizontalni rad, mala brzina vrtnje rezne glave, kontinuirani kontakt reznog elementa sa svježim tlom i kontinuirano ubrizgavanje aditiva uz specifični tlak tijekom pokusa. Analiziran je učinak udio sitnozrnatih čestica, vlažnosti tla i omjera ubrizgavanja pjene (FIR) na začepljenje, utrošenu energiju i prosječno trošenje reznog alata. Rezultati su pokazali da se povećanjem postotka sitnih čestica tla s 90 na 100% začepljenje reznih alata povećava za 50%. Također, povećanjem vlažnosti tla od suhog stanja do vlažnosti od 5% začepljenje rezne glave je neznatno, a nakon toga, povećanjem vlage od 10 do 25% začepljenje se povećava za 178% dok se količina potrošene energije u svakom pokusu povećava se za 84%. Uz to, povećanjem omjera ubrizgavanja pjene s 40% na 60%, začepljenje se smanjilo u prosjeku za 81%, a trošenje reznog alata u prosjeku je smanjeno za 62%

    Evaluation of excavated surface irregularities and hardness of mechanical excavations and their relationship with excavator performance

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    This research involved lab and numerical excavation of a clastic sedimentary rock (Roubidoux Sandstone) using a long-bladed disc cutter in a Linear Rock Cutting Machine (LCM) with the aim of establishing relationships between the cutting parameters, excavated surface parameters (underbreaks, overbreaks and hardness), and performance parameters (specific energy and cutting rate). Three-dimensional cutting forces were recorded during the linear cutting. A structured laser imaging system was used to image the excavated surfaces for the estimation of the irregularities (ridge volumes (RV) and overbreak volumes (OV)). The excavated surface hardness was measured using the N-type Schmidt hammer. The numerical simulation was conducted in Itasca’s Particle Flow Code 3D (PFC3D). It involved model calibration, a study of the effects of the cutting geometry and cutter scale on the cutting forces, validation of the models using the lab cutting data, and a study of the effects of cutter size on the cutting forces. The results showed that the RV increased with increasing spacing-penetration (s-p) ratio for s-p ratios at which relieved cutting was achieved. However, the RV decreased with increasing s-p ratio under unrelieved cutting. The OV had a negative linear correlation with the s-p ratio under relieved cutting. In unrelieved cutting, the OV was independent of the s-p ratios. These findings can be used to determine the s-p ratio at which relieved cutting is first achieved. The specific energy decreased linearly with increasing surface hardness. The hardness was used together with the s-p ratio to develop a function for estimating SE. The numerical models yielded logarithmic functions for scaling forces from linear rock cutting simulations in PFC3D --Abstract, page iii

    Saturation effects on mechanical excavatability of Roubidoux sandstone under selected rock cutting tools

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    This study investigated the differences in the cutting performance of two rock cutting tools in dry and saturated rock. For this purpose, a permeable quartzose sandstone was subjected to a series of full scale linear rock cutting tests, in both dry and saturated conditions, using a constant cross-section (CCS) disc cutter and a radial drag pick at a constant cutting speed. In this rock, saturation with water reduced the forces acting on the disc cutter by 27-48% (significant at 90% confidence), but also reduced the chip yield by nearly as much. Even though the specific energy of fragmentation went down 8-10%, the difference was not statistically significant. Contrary to the behavior under the disc cutter, water saturation increased the drag pick cutting forces by 9-10%, which is suggestive but not enough to be statistically significant. It did not increase the chip yield by a concomitant amount, however, so the specific energy went up by 28% (significant at 90% confidence). The unexpected differences in the effect of water saturation on the rock fragmentation response to these cutters might be explained by the effects due to their different fragmentation mechanisms, such as the relative size of the crushed zone that forms beneath the cutters. The relationship between cutting speed and rock permeability was expected to be a major factor influencing the effective pressure beneath a cutter in saturated rock. However, load-indentation tests with pore pressure measurement at the same speed showed that the pore pressure within the tested sandstone remained too low to affect the rock fracture process. Other possible mechanisms are discussed --Abstract, page iii

    Theoretical and Experimental Results from Laboratory Tests by ILCM

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    The Intermediate Linear Cutting Machine (ILCM) is a machine designed to work on an intermediate scale between the full- and the small-scale. The reduced scale involves several advantages compared to full-scale tests, especially in terms of sample supplying and transportation. On the other hand, it has an impact on the testing conditions, resulting in a limitation of the cutting penetration and spacing during the test, as well as in a smaller disc cutter. This affects most of the results, which cannot be directly used for the on-site machine performance prediction. However, some experimental results provided in the literature show that the optimal spacing/penetration ratio is not significantly affected by the changes involved. On this basis, the results obtained from ILCM tests should provide reliable information about the optimal cutting conditions of a tunnel boring machine (TBM) in massive rock mass. The work performed included the development of some improvements of the testing rig, as well as a modified ILCM testing procedure, according to the one typically used in standard LCM tests. The results provide information about the attitude of the tested lithotypes to mechanical excavation by means of disc tools, including the optimal cutting conditions. Additional work was developed in terms of detailed characterization of the rock samples involved and assessment of the size distribution of the debris produced during the ILCM tests. Nevertheless, further tests are necessary, in order to assess the consistency of the experimental procedure employed and to investigate the scale effect
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