盾构刀盘轻量化优化设计研究
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摘要
刀盘是盾构掘进机的关键部件,受地质环境和土体特性的影响,其设计技术十分复杂,是盾构机设计的关键技术之一。而且刀盘结构件自重大,合理减轻刀盘质量可有效地节省装备制造成本、减低能耗、节省运营成本。因此研究刀盘的轻量化设计技术有重要意义。
本文从研究盾构刀盘上的载荷入手,对满足强度和刚度需求的刀盘轻量化优化设计展开研究。主要内容和结果如下：
(1)关于常用土压力理论和刀具切削理论的研究。本研究将临界埋深下的土压计算值和成都地铁工程实测值进行了比较,完成了土压力公式的选用。分析了刀具受力与刀具物理尺寸、围岩物理参数之间的关系。为研究刀盘载荷打下基础。
(2)多工况刀盘载荷模型研究。研究了刀盘和工作面的作用关系,建立了刀盘载荷模型。根据实际工程参数,计算了多工况下的刀盘载荷,并通过成都地铁实测数据校对了计算载荷值。为虚拟样机模型的载荷加载提供数据。
(3)刀盘结构有限元分析。以成都地铁1号线φ6.28m盾构机刀盘为分析对象,分析了多种工况下刀盘的强度和刚度,确定了危险工况。该分析可为轻量化优化设计提供依据和数据。
(4)刀盘的轻量化优化设计研究。以盾构刀盘为研究对象,运用ANSYS有限元软件进行优化计算,取得优化结果并校核。通过轻量化优化设计,刀盘质量减少5.61t,相比原刀盘轻14.15%。
The cutter head is a key component of the shield machine. By the effects of geological environment and soil characteristics, the design process is considerable complex, which is one of the key technologies in shield machine design. The heavy cutter head result in high manufacturing costs, energy consumption and operational costs, which can be reduced effectively by reducing the weight of the cutter head.
Started from the loads on the cutter head, this article is focused on the weight lightening optimization design of cutter head, which still satisfies the requirements of strength and stiffness. The contents and results of this paper are as follows:
(1) Study on common earth pressure theory and tool loading theory. In this study, the critical depth pressure value from calculation is compared with the measured values in Chengdu Metro Project to pick the suitable earth pressure formula. The relation between the tool load and its physical size, parameters of surrounding rocks is also analyzed, which laid the foundation for studying the loads on the cutter head.
(2) Study on the load model of cutter head under multi-conditions. The relation of the cutter head and excavation plane is studied, and the load model of multi-condition is established. According to the parameters got from the real projects, the loading under multi-conditions are calculated, which are also supported by the data acquired from Chengdu Metro Project. Loading data for the virtual prototype model can be provided by this study.
(3) Finite Element Analysis of cutter head. The Chengdu Subway Line1φ6.28m shield cutter head is set as analysis object. The dangerous conditions are found by the analysis of its strength and stiffness under multi working conditions. The supporting evidences and data for weight lightening optimization design can be provided by this analysis.
(4) Study on weight lightening optimization design of cutter head. ANS YS is applied to achieve the optimization of φ6.28m shield cutter head. After optimization, the weight of final result is decreased by5.61tons,14.15%lighter than the original cutter head.
本文从研究盾构刀盘上的载荷入手,对满足强度和刚度需求的刀盘轻量化优化设计展开研究。主要内容和结果如下：
(1)关于常用土压力理论和刀具切削理论的研究。本研究将临界埋深下的土压计算值和成都地铁工程实测值进行了比较,完成了土压力公式的选用。分析了刀具受力与刀具物理尺寸、围岩物理参数之间的关系。为研究刀盘载荷打下基础。
(2)多工况刀盘载荷模型研究。研究了刀盘和工作面的作用关系,建立了刀盘载荷模型。根据实际工程参数,计算了多工况下的刀盘载荷,并通过成都地铁实测数据校对了计算载荷值。为虚拟样机模型的载荷加载提供数据。
(3)刀盘结构有限元分析。以成都地铁1号线φ6.28m盾构机刀盘为分析对象,分析了多种工况下刀盘的强度和刚度,确定了危险工况。该分析可为轻量化优化设计提供依据和数据。
(4)刀盘的轻量化优化设计研究。以盾构刀盘为研究对象,运用ANSYS有限元软件进行优化计算,取得优化结果并校核。通过轻量化优化设计,刀盘质量减少5.61t,相比原刀盘轻14.15%。
The cutter head is a key component of the shield machine. By the effects of geological environment and soil characteristics, the design process is considerable complex, which is one of the key technologies in shield machine design. The heavy cutter head result in high manufacturing costs, energy consumption and operational costs, which can be reduced effectively by reducing the weight of the cutter head.
Started from the loads on the cutter head, this article is focused on the weight lightening optimization design of cutter head, which still satisfies the requirements of strength and stiffness. The contents and results of this paper are as follows:
(1) Study on common earth pressure theory and tool loading theory. In this study, the critical depth pressure value from calculation is compared with the measured values in Chengdu Metro Project to pick the suitable earth pressure formula. The relation between the tool load and its physical size, parameters of surrounding rocks is also analyzed, which laid the foundation for studying the loads on the cutter head.
(2) Study on the load model of cutter head under multi-conditions. The relation of the cutter head and excavation plane is studied, and the load model of multi-condition is established. According to the parameters got from the real projects, the loading under multi-conditions are calculated, which are also supported by the data acquired from Chengdu Metro Project. Loading data for the virtual prototype model can be provided by this study.
(3) Finite Element Analysis of cutter head. The Chengdu Subway Line1φ6.28m shield cutter head is set as analysis object. The dangerous conditions are found by the analysis of its strength and stiffness under multi working conditions. The supporting evidences and data for weight lightening optimization design can be provided by this analysis.
(4) Study on weight lightening optimization design of cutter head. ANS YS is applied to achieve the optimization of φ6.28m shield cutter head. After optimization, the weight of final result is decreased by5.61tons,14.15%lighter than the original cutter head.
引文
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