TBM刀盘系统破岩能量特性分析及集成化设计理论研究

In the TBM tunnel construction, machine parameters, construction parameters and the rock mechanics properties do not match well with each other frequently, it leads to serious damage of cutterhead system, high failure rate of the whole machine, high energy consumption and low boring performance. To solve the above problems, the project will focus on the research of energy characteristics in the coupling relations between the cutterhead system and hard rock mass, through the actual project cutter head system excavates rock process to analysis mechanical physical properties, and according to the energy as the main line make the research unification, a coupling model based on energy characteristics in the cutter head system and hard rock mass will be established to analysis the formation of the energy field under single and multi-point impelling by the cutter, as well as rock mass by loading energy transfer and transformation rule, bringing forward cutter head system breaks rock mass mechanism based on energy characteristics. Furthermore, the model will be used to explore the influence of different region cutters distribution for the forming of energy field, effect and efficiency of rock breaking, to research the unloading energy effect of the excavation by cutter group to surrounding rock at different working condition, to form disc cutter layout theory and the cutter head topology structure design method based on energy field, to establish the cutter head system performance evaluation system, make the TBM fast and effective construction guidance. Finally, a relatively complete theory of TBM cutter head system design will be formed containing the “Engineering problems–Design method-Performance evaluation” for complicated geological condition the cutter head system design theory.

针对TBM施工过程中，经常出现由于刀盘系统结构参数、掘进控制参数和岩体力学特性不匹配，而导致的刀盘系统破损失效严重、整机故障率高、能耗大、掘进性能低等问题，围绕“刀盘系统与硬岩间耦合作用中的能量特性”这一科学问题，通过对实际工程中刀盘系统开挖岩体过程力学物理特性分析，以能量为主线进行统一化研究，建立刀盘系统-硬岩能量特性模型，分析滚刀单/多点激励下的能量形成以及受载岩体中的能量传递转化规律，提出基于能量特性的刀盘系统破岩机理；探索分区域滚刀布局对能量形成、破岩有效性和破岩效率的影响；研究不同掘进工况下，滚刀布局对围岩的开挖能量卸荷效应；形成基于能量特性的分区域滚刀布局理论和刀盘拓扑结构设计方法；建立刀盘系统性能评价体系，指导硬岩掘进机快速有效施工，最终形成较为完整的涵盖“工程问题-设计方法-性能评价”的适应复杂地质条件的TBM刀盘集成设计理论。

针对TBM施工过程中，经常出现由于刀盘系统结构参数、掘进控制参数和岩体力学特性不匹配，而导致的刀盘系统破损失效严重、整机故障率高、能耗大、掘进性能低等问题。围绕“刀盘系统与硬岩间耦合作用中的能量特性”这一科学问题，通过对实际工程中刀盘系统开挖岩体过程力学物理特性分析，以能量为主线进行统一化研究。通过对盘形滚刀破岩过程中的能量传递与转化研究，建立了基于能量守恒方程的刀盘系统-硬岩能量特性模型；提出了基于能量特性的刀盘系统破岩机理；从静力学、动力学两个方面建立了基于能量原理的盘形滚刀破岩预测模型，通过工程实例验证动力学盘形滚刀载荷受力预测模型更能反映出掘进机工程施工过程中的盘形滚刀空间域及时间域的动态破岩特性；通过基于热传导理论的盘形滚刀破岩热能分析，明确了盘形滚刀破岩过程中的温度变化及在刀盘上的分布特性；针对刀盘的拓扑结构优化问题，提出了基于破岩比能的刀盘滚刀优化布局设计、基于免疫算法的盘形滚刀能量布局设计、基于掌子面稳定性约束的滚刀极径优化、基于刀盘冲击能均衡分布约束的滚刀极角优化等多种设计方法；提出了评判刀具布局性能优劣的四个评价指标：倾覆力矩、径向不平衡力、刀具质量偏心和刀盘破岩能偏心；建立了TBM刀盘布局性能的多目标评价方法，并形成了刀盘系统性能评价体系，能够指导硬岩掘进机快速有效施工。.项目研究成果最终形成了较为完整的涵盖“工程问题-设计方法-性能评价”的适应复杂地质条件的TBM刀盘集成设计理论。本研究对于突破国外技术封锁，提高我国自主创新设计与制造能力，进一步加快TBM 国产化进程，降低施工成本，乃至提升我国制造业技术水平具有重要的学术价值、实际意义和广泛的应用前景。