三高环境下TBM刀盘破岩机理与设计方法研究

Full face hard rock tunnel boring machine(TBM) is current the major key equipment for our country to study and master. The cutterhead is the decisive factors influencing the performance of TBM, and also the key and difficulty for TBM design. Due to lack knowledge of rock fragmentation mechanism for cutterhead under the complex geology at present, the cutterhead geological adaptiveness is poor, causing engineering phenomenon such as TBM machine vibration, cutter tool severe wear and earth surface collapse. To solve the above problems, we intend to adopt the combined methods of theory analysis, experiment test and engineering testing to analyze the geological parameters and properties of surrounding rock. Based on the rock fragmentation mechanism under TBM cutter group to research load formation, distribution and transfer laws for cutterhead under the complex geology and to study vibration generation mechanism, fatigue damage characteristics and disc cutter failure mechanism for cutterhead under impact load, and then we take cutting performance, load distribution balance and dynamic stability as target to establish multi-parameter coupling design model of cutterhead system, and propose a complete geological suitability design theory of cutterhead system and a multi-level evaluation approach for cutterhead performance，and achieve overall performance optimization for cutterhead system .

全断面硬岩隧道掘进机（TBM）是当前我国重大工程急需的关键装备。刀盘是影响TBM掘进性能的决定性因素，也是TBM设计的关键和难点。由于目前对复杂地质下刀盘破岩机理认识不足，致使刀盘地质适应性匹配较差，从而造成TBM整机剧烈振动、刀盘刀具严重磨损、甚至设备完全损坏等重大工程问题。针对上述难题，本项目拟采用理论分析、实验测试和工程检验相结合的方法，对地质参数和围岩属性进行分析，基于TBM刀群破岩机理，研究刀盘系统在复杂地质环境掘进时破岩阻力形成、分布与传递规律以及冲击载荷作用下刀盘系统振动产生机理、刀盘疲劳损伤特性和盘形滚刀失效机理，在此基础上以刀盘切削性能、载荷分布均衡性和动力学稳定性为目标建立刀盘系统多参数耦合设计模型，提出一套完整的刀盘系统地质适应性设计理论与多层次指标刀盘性能评价方法，实现刀盘系统整体性能优化设计。

由于目前对复杂地质下刀盘破岩机理认识不足，导致刀盘地质适应性匹配能力差，刀盘刀具损耗严重。本项目从刀盘滚刀群破岩真实工况出发，系统地研究了刀盘系统破岩阻力的形成、分布以及传递规律，建立了一种刀盘综合性能评价方法，具体主要包括以下方面：.1、研究了多滚刀组合切削下岩石内部裂纹扩展规律和破碎模式，确定了岩石破碎机理为压剪张拉综合破碎。建立了滚刀群载荷预测模型，分析了刀盘掘进载荷分布规律以及多参数综合交互作用对其的影响显著性程度。.2、通过刀圈岩石对摩实验，揭示了刀圈磨损机理，建立了滚刀刃型磨损预测模型，确定了刀圈硬度、冲击韧性的匹配规律。建立了刀圈成形和热处理工艺数值模型，优化了刀圈制造工艺。.3、建立了滚刀-刀座系统载荷传递动力学模型，分析了脉冲动载下刀座系统动态响应特性。研究了不同岩石和刀盘参数等对刀盘系统振动的影响规律，揭示了振动在刀盘系统中的传递规律。.4、建立了滚刀地质适应性结构优化和布置模型，提出了刀盘出碴系统结构优化设计方法。研究了盘体结构参数对刀盘静动态性能的敏感程度及影响规律。建立了TBM刀盘性能评价指标体系和梯阶层次结构评价模型，并利用TOPSIS和灰色关联度法对刀盘结构性能进行综合决策。