CN103235880A - Method for predicting service life of disc cutter by using radial wear coefficient - Google Patents

Abstract

The invention belongs to the technical field of service life prediction of disc cutters, and particularly relates to a method for predicting service life of a disc cuter by using a radial wear coefficient. A prediction result with prediction precision improved obviously in comparison with that of a prediction method by using an axial wear coefficient can be obtained through multiple steps of calculating the radial wear coefficient of the disc cutter on a cutter head of a full face TBM (Tunnel Boring Machine), correcting the radial wear coefficient of the disc cutter and predicting the service life of the disc cutter on the cutter head of the full face TBM; and the method for predicting the service life of the disc cuter by using the radial wear coefficient can be utilized in engineer operations efficiently.

Description

With the gauge wear coefficient disk cutter life-span is carried out forecast method

Technical field

The invention belongs to disk cutter forecasting technique in life span field, particularly a kind ofly with the gauge wear coefficient disk cutter life-span is carried out forecast method.

Background technology

Axially the coefficient of waste is the normally used method of prediction disk cutter wear extent on the present engineering.Certain engineering is 7.87mm with the complete-section tunnel boring machine mean penetration, the wear extent of the corresponding cutter spacing disk cutter of the follow-up engineering of axial resultant wear coefficient prediction (mean penetration 5.02m, Excavation Length 5621m) of each cutter spacing disk cutter and all bigger with deviation, relative deviation and the relative deviation mean value of actual wear amount contrast generation on the cutterhead that driving 173m determines.The extreme difference that produces with the positive hobboing cutter wear extent of axial resultant wear coefficient prediction occurs in cutter spacing No. 45, and extreme difference is 317.89mm, and corresponding relative error is 25.76%; The extreme difference that prediction transition hobboing cutter wear extent produces occurs in cutter spacing No. 59, and extreme difference is 1171.37mm, and corresponding relative error is 51.11%; The relative deviation mean value that forecasting institute is surveyed all positive hobboing cutter wear extent generation is 37.70%, it is 46.08% that forecasting institute is surveyed the relative deviation mean value that whole transition hobboing cutter wear extenies produce, forecasting institute survey relative deviation mean value that whole hobboing cutter wear extenies produce be 41.20%(this with engineering on method therefor predict that the objective and accurate rate of disk cutter wear-out life is about 40% conclusion basically identical).

Therefore, about 40% relative deviation is also not accurate enough, in actual engineering, has much room for improvement.

Summary of the invention

The invention provides and a kind ofly with the gauge wear coefficient disk cutter life-span is carried out forecast method, can make its precision of prediction axially coefficient of waste Forecasting Methodology be significantly improved.

The technical solution used in the present invention is:

Adopt the gauge wear coefficient that the disk cutter life-span is carried out forecast method, the branch following steps are carried out:

(1) calculate disk cutter gauge wear coefficient on the complete-section tunnel boring machine cutterhead:

Definition disk cutter gauge wear coefficient is that the broken rock point of disk cutter sword is once invaded the radial wear that dark broken rock motion produces on the complete-section tunnel boring machine cutterhead, uses k _rExpression, its unit is that mm/ changes;

Then:

, wherein, L is complete-section tunnel boring machine driving total length, and h is cutterhead revolution cutting-in, and the total revolution of cutterhead when then complete-section tunnel boring machine driving total length is L is

R is the disk cutter radius, and R is trace radius, and then the revolution of disk cutter is during the cutterhead revolution

M is the disk cutter wear extent; When complete-section tunnel boring machine Excavation Length L, the broken rock number of times of certain point is on the disk cutter

(2) disk cutter gauge wear coefficient is revised:

The pile penetration correction factor of the positive cutter coefficient of waste of definition disk cutter is k _S1,

Then,

, wherein,

$s=\frac{2}{R}\left[\sqrt{\frac{r}{2}}\·\sqrt{2r{R}^2+2r^3}+R^2\ln \left(r\·\sqrt{2r}+\sqrt{2r{R}^2+2r^3}\right)?\frac{\sqrt{2r?h}}{2}\sqrt{2r{R}^2+r^2\left(2r?h\right)}?R^2\ln \left(r\·\sqrt{2r?h}+\sqrt{2r{R}^2+r^2\left(2r?h\right)}\right)\right]$ ， $s_0=\frac{2}{R}\left[\sqrt{\frac{r}{2}}\·\sqrt{2r{R}^2+2r^3}+R^2\ln \left(r\·\sqrt{2r}+\sqrt{2r{R}^2+2r^3}\right)?\frac{\sqrt{2r?h_0}}{2}\sqrt{2r{R}^2+r^2\left(2r?h_0\right)}?R^2\ln \left(r\·\sqrt{2r?h_0}+\sqrt{2r{R}^2+r^2\left(2r?h_0\right)}\right)\right]$ ，

In the formula, s ₀For the sondage section of advancing disk cutter sword connects rock forward point to the maximum arc length of passing by when dark of invading in rock, s connects rock forward point to the maximum arc length of passing by when dark, the h of invading for driving section disk cutter sword in rock ₀Be the sondage section of advancing disk cutter pile penetration;

The pile penetration correction factor of the transition disk cutter coefficient of waste is k on the definition cutterhead _S2,

Then, $k_{s2}=\frac{h_0}{h}$ ；

(3) the disk cutter life-span on the complete-section tunnel boring machine cutterhead is predicted:

Disk cutter prediction wear extent formula is on the cutterhead:

。

Beneficial effect of the present invention is:

Still at the Engineering Projects of mentioning in the background technology, predict that with the axial coefficient of waste extreme difference that positive hobboing cutter wear extent produces reduces 317.89-119.47=198.42mm at experimental section with the extreme difference of the radially positive hobboing cutter wear extent generation of resultant wear coefficient prediction; The extreme difference that transition hobboing cutter wear extent produces reduces 1171.37-880.29=291.08mm at experimental section; With the positive hobboing cutter wear extent of No. 45 cutter spacing of resultant wear coefficient prediction radially with the positive hobboing cutter wear extent of axial this cutter spacing of resultant wear coefficient prediction precision improve 25.76-16.38%=9.38%, institute surveys positive hobboing cutter wear extent precision raising 37.7%-15.48%=22.22%, the transition hobboing cutter wear extent precision of surveying raising 46.08%-16.58=29.5%, whole cutter spacing hobboing cutter wear extent precision raising 41.20%-16.12%=25.08% that survey.Therefore, its wear extent of radially resultant wear coefficient prediction (life-span) with disk cutter significantly improves with the precision of axial resultant wear coefficient prediction.

Embodiment

The invention provides and a kind ofly with the gauge wear coefficient disk cutter life-span is carried out forecast method, the present invention will be further described below by embodiment.

Adopt the gauge wear coefficient that the disk cutter life-span is carried out forecast method, the branch following steps are carried out:

(1) calculate disk cutter gauge wear coefficient on the complete-section tunnel boring machine cutterhead:

Definition disk cutter gauge wear coefficient is that the broken rock point of disk cutter sword is once invaded the radial wear that dark broken rock motion produces on the complete-section tunnel boring machine cutterhead, uses k _rExpression, its unit is that mm/ changes;

Then: , wherein, L is complete-section tunnel boring machine driving total length, and h is cutterhead revolution cutting-in, and the total revolution of cutterhead when then complete-section tunnel boring machine driving total length is L is

R is the disk cutter radius, and R is trace radius, and then the revolution of disk cutter is during the cutterhead revolution M is the disk cutter wear extent; When complete-section tunnel boring machine Excavation Length L, the broken rock number of times of certain point is on the disk cutter

(2) disk cutter gauge wear coefficient is revised:

The factor that influences the complete-section tunnel boring machine disk cutter coefficient of waste is not only many but also complicated, except the physical function parameter of the geometric shape parameters of disk cutter self and material thereof, also comprise geo-logical terrain parameter (as: construction country rock type, country rock characteristics---crack and weak plane etc.), the performances of rock parameter is (as tensile strength, compressive strength, shearing strength and hardness etc.) and boring parameter (as pile penetration, the cutterhead rotating speed) etc., the physical function parameter of the geometric shape parameters of disk cutter self and material thereof wherein, geo-logical terrain parameter and performances of rock parameter are fit to do special examination (reality) to the influence of the disk cutter coefficient of waste and test and study.In fact, above-mentioned parameter is not what isolate to the influence of construction disk cutter wearing and tearing, but influence each other, mutual restriction and interactional.The excavation operation of disk cutter in the geo-logical terrain of basically identical of just certain material and geometric configuration, the difference of its position on cutterhead, abrasion condition also has larger difference.Positive hobboing cutter district on cutterhead, certain rule is followed in the wearing and tearing of disk cutter substantially; And at the disk cutter of cutterhead zone of transition, its wear condition is again another situation.

Disk cutter in the positive hobboing cutter of cutterhead district, to invade the arc length of passing by in rock when dark be s to maximum if the sondage section of advancing disk cutter sword connects rock forward point ₀, driving section disk cutter sword connects rock forward point, and to invade the arc length of passing by in rock when dark be s to maximum, the pile penetration correction factor k of the disk cutter coefficient of waste _sExpression, then, the quality better of driving section rock if the quality of driving section rock is had a competition, disk cutter is just little in the pile penetration of driving section, that is: s＜s ₀, at this moment, the distribution pressure that disk cutter connects on the rock sword advances Duan Weida than sondage, and the disk cutter wearing and tearing increase, and should have: k _s1; If the poor quality that the quality of driving section rock is had a competition driving section rock, disk cutter is just big in the pile penetration of driving section, that is: s〉s ₀, at this moment, the distribution pressure that disk cutter connects on the rock sword advances Duan Weixiao than sondage, and the disk cutter wearing and tearing slow down, and should have: k _s＜1.

The pile penetration correction factor of the positive cutter coefficient of waste of definition disk cutter is k _S1,

Then,

, wherein,

$s=\frac{2}{R}\left[\sqrt{\frac{r}{2}}\·\sqrt{2r{R}^2+2r^3}+R^2\ln \left(r\·\sqrt{2r}+\sqrt{2r{R}^2+2r^3}\right)?\frac{\sqrt{2r?h}}{2}\sqrt{2r{R}^2+r^2\left(2r?h\right)}?R^2\ln \left(r\·\sqrt{2r?h}+\sqrt{2r{R}^2+r^2\left(2r?h\right)}\right)\right]$ ， $s_0=\frac{2}{R}\left[\sqrt{\frac{r}{2}}\·\sqrt{2r{R}^2+2r^3}+R^2\ln \left(r\·\sqrt{2r}+\sqrt{2r{R}^2+2r^3}\right)?\frac{\sqrt{2r?h_0}}{2}\sqrt{2r{R}^2+r^2\left(2r?h_0\right)}?R^2\ln \left(r\·\sqrt{2r?h_0}+\sqrt{2r{R}^2+r^2\left(2r?h_0\right)}\right)\right]$ ，

At the disk cutter of cutterhead zone of transition, because of its plane, blade place scar out of plumb broken with it, but one-tenth is greater than 90 ° obtuse angle, therefore, the wearing and tearing of transition disk cutter are responsive to the pile penetration of disk cutter, so the pile penetration correction factor of the transition disk cutter coefficient of waste is k on the definition cutterhead _S2,

Then, $k_{s2}=\frac{h_0}{h}$ ；

(3) the disk cutter life-span on the complete-section tunnel boring machine cutterhead is predicted:

Disk cutter prediction wear extent formula is on the cutterhead:

。

Embodiment

(1) measurement of the coefficient of waste

The coefficient of waste of disk cutter can carry out in the complete-section tunnel boring machine sondage section of advancing or in certain part of its normal driving section, and carry out the record of country rock type, characteristics (as crack, weak plane etc.), performances of rock parameter (as tensile strength, compressive strength, shearing strength, hardness) and boring parameter (as pile penetration, cutterhead rotating speed) etc., in order to provide reference frame for the life prediction of similar engineering construction disk cutter.As: certain Tunnel Engineering is shown in Table 1 with complete-section tunnel boring machine disk cutter and relative dimensions parameter thereof, and the mean penetration in driving 173m process is 7.87mm, and the wear extent of each cutter spacing is shown in Table 1, and the gauge wear coefficient also is recorded in the table 1.

Table 1 certain the tunnel complete-section tunnel boring machine sondage section of advancing part disk cutter correlation parameter and coefficient of waste

(2) disk cutter wear extent prediction

Use in the described engineering that the complete-section tunnel boring machine driving is long to be one section tunnel of 5621m.In this driving section, the disk cutter mean penetration is 5.02mm, and the actual wear amount of each cutter spacing disk cutter is shown in Table 2.According to the coefficient of waste shown in the table 1, the wear extent that dopes this driving section disk cutter is recorded in the table 2.

The disk cutter of certain Tunnel Engineering TBM driving 5621m of table 2 calculates wear extent and actual wear amount

Deviation, relative deviation and relative deviation mean value with the radially wear extent generation of the corresponding cutter spacing disk cutter of the follow-up engineering of resultant wear coefficient prediction (mean penetration 5.02m, Excavation Length 5621m) are shown in Table 3.As can be seen from Table 3, use the extreme difference of the radially positive hobboing cutter wear extent generation of resultant wear coefficient prediction to occur in cutter spacing No. 45, be 119.47mm, corresponding relative error is 14.26%; Extreme difference with radially resultant wear coefficient prediction transition hobboing cutter wear extent generation occurs in cutter spacing No. 61, be 880.29mm, corresponding relative error is 48.14%, the relative deviation mean value that forecasting institute is surveyed all positive cutter wear extent generation is 15.48%, the relative deviation mean value that forecasting institute is surveyed whole transition hobboing cutter wear extenies generations is 16.58%, and the relative deviation mean value that forecasting institute is surveyed whole hobboing cutter wear extenies generations is 16.112%.

By table 3 as can be seen, adopt the gauge wear coefficient that the disk cutter life-span is predicted that its precision is significantly improved than the axial factor predicted method.

Claims (1)

1. with the gauge wear coefficient disk cutter life-span is carried out forecast method, it is characterized in that, the branch following steps are carried out:

(1) calculate disk cutter gauge wear coefficient on the complete-section tunnel boring machine cutterhead:

Definition disk cutter gauge wear coefficient is that the broken rock point of disk cutter sword is once invaded the radial wear that dark broken rock motion produces on the complete-section tunnel boring machine cutterhead, uses Expression, its unit is that mm/ changes;

Then:

, wherein, L is complete-section tunnel boring machine driving total length, and h is cutterhead revolution cutting-in, and r is the disk cutter radius, and R is trace radius, m is the disk cutter wear extent;

(2) disk cutter gauge wear coefficient is revised:

The pile penetration correction factor of the positive cutter coefficient of waste of definition disk cutter is k _S1,

Then,

, wherein,

，

，

In the formula, s ₀For the sondage section of advancing disk cutter sword connects rock forward point to the maximum arc length of passing by when dark of invading in rock, s connects rock forward point to the maximum arc length of passing by when dark, the h of invading for driving section disk cutter sword in rock ₀Be the sondage section of advancing disk cutter pile penetration;

The pile penetration correction factor of the transition disk cutter coefficient of waste is k on the definition cutterhead _S2,

Then,

(3) the disk cutter life-span on the complete-section tunnel boring machine cutterhead is predicted:

Disk cutter prediction wear extent formula is on the cutterhead:

。