盾构机盘形滚刀作用下岩石破碎特征及滚刀振动特性研究
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摘要
近年来,盾构机在水利水电涵洞、城市地下工程、海河地下隧洞及矿山、山区铁路、公路隧道施工中得到了越来越广泛的应用。盘形滚刀是盾构机刀盘上主要的掘进刀具,其切削性能直接影响了盾构机的掘进效率。本文来源于国家973项目子课题——“岩土切削机理与刀盘设计理论”,主要围绕切削过程中岩土的破碎特征及滚刀垂直方向的振动特性进行研究,以期改进滚刀的结构设计,提高滚刀的使用寿命及适应性,优化盘形滚刀在刀盘上的布置,最终实现高效、低能耗的隧道掘进。
本文主要进行了如下的工作：
(1)在对滚刀实际破岩运动进行运动学分析的基础上,合理简化问题,分别建立了单一特定地层条件下单刀切割含倾斜节理岩石、双刀切割节理不发育岩石以及含水平节理岩石的二维数值模型,仿真观察到岩石在不同围压、节理参数、刀间距和切削顺序下微裂纹的演化过程,并根据裂纹扩展方向和破碎块的形成规则不同,总结归纳出盾构刀具切割岩土时的12种典型破碎模式。最后从破岩效率,裂纹扩展能力,岩石破碎块度等方面对岩土破碎特性展开深入分析。
(2)将赫兹弹性接触理论引入离散单元法建模,并考虑刀具的初始应力分布对裂纹扩展的影响,建立了包含刃形特性的双刃球齿滚刀侵入砂岩的离散元模型。通过对比分析得出了刀具侵入岩石时,刃形对岩土破碎特征的影响规律。
(3)在单把滚刀与岩石构成的系统中,岩石的跃进破碎特性及滚刀特有的蛇行现象,使得滚刀在切削过程中不可避免的发生振动。本文分别采用位移约束及力约束作为滚刀的下端边界条件,建立了适用于滚刀滚压硬、软岩和土壤的一般垂直振动微分方程,并对实验用滚刀进行了算例分析。
(4)在现有线切割试验台的基础上设计了双刃球齿滚刀侵入砂岩的观测试验。利用高速摄像仪成功捕捉到了岩石的崩裂现象,并巧妙地使用普通数码相机不连续地记录了密实核的形成过程,验证了相关结论。
(5)设计了实验用盘形滚刀,并在原有线切割试验台上进行切割混凝土的实验。观测到了混凝土的宏观破坏现象、获得了三向力的特征及岩石破碎块度的变化规律。
Recently, shield machine was widely used in many areas, such as construction of water conservancy and hydropower culverts, urban underground engineering and construction of artificial canal, underground tunnel, mine, mountain railway and highway tunnel. As one of the main cutters of shield machine in the cutterhead, disc cutter's cutting performance directly affects the excavation efficiency of shield machine. The paper comes from the topic "cutting mechanism of rock and theory of cutterhead design", which is the sub-project of the National Key Basic Research and Development Program of China (973 Program). The paper has attached great importance to rock-fragmentation characteristics and vertical cutting vibration, in order to improve structure design, tool life, adaptability of the cutter, optimize tool configuration in cutterhead and achieve the aims of 1 and lower energy consumption in tunnel excavation.
The paper complete contents as below:
1) Based on kinematics analysis of rock-fragmentation process of disc cutter, reasonably simplifying the problem, respectively building 2-D discrete element models of single cutter breaking rock with inclined joints, double cutters breaking rock without joints and with horizontal joints under the condition of single specific formation, the crack propagation of microcrack under different confined pressures, parameters of joints, cutter spacing and cutting orders was observed. Based on the propagation direction of crack and the formation rule of fragment,12 typical types of breaking modes while breaking rock by TBM cutters were concluded. Finally, the rock-fragmentation characteristics was analyzed in the respects of efficiency of breaking rock, the propagation ability of crack and rock broken lumpiness.
2) Considering the effects of initial stress distribution of the cutters on crack propagation, Hertz elastic contact theory was introduced into the simulation. A discrete finite element model indenting into sandstone by TBM double-edged spherical tooth hob was established. Comparing the simulation and literature results, the influence law of cutting edge shape on rock-fragmentation characteristics during breaking process was acquired.
3) In the vibration system consisting of a single disc cutter and rock, the cutter is inevitably quivering during the breaking process because of the characteristics of step-crushing and the snake-like phenomenon. The general differential equations of vertical vibration of disc cutter suitable for breaking hard rock, soft rock and soil were respectively established by adopting displacement constraint and force constraint as the lower boundary condition. Taking the disc cutter designed for experiments mentioned in this paper rolling granite as the example, the dynamic simulation analysis was done.
4) Based on the existing linear cutting test-bed, an observation experiment is designed, in which double-edged spherical tooth hob indents into sandstone. The phenomena of rock crushing and bursting were captured by the high speed camera successfully and the formation process of compacting rock core was discontinuously recorded by the general digital camera skillfully. The related theory derived from the simulation result was verified.
5) The experiment of the designed cutter rolling concrete was carried out on the test-bed. The macroscopical phenomenon of concrete-crushing was observed, the changing law of rock broken lumpiness and the characteristics of three-axis force were obtained.
本文主要进行了如下的工作：
(1)在对滚刀实际破岩运动进行运动学分析的基础上,合理简化问题,分别建立了单一特定地层条件下单刀切割含倾斜节理岩石、双刀切割节理不发育岩石以及含水平节理岩石的二维数值模型,仿真观察到岩石在不同围压、节理参数、刀间距和切削顺序下微裂纹的演化过程,并根据裂纹扩展方向和破碎块的形成规则不同,总结归纳出盾构刀具切割岩土时的12种典型破碎模式。最后从破岩效率,裂纹扩展能力,岩石破碎块度等方面对岩土破碎特性展开深入分析。
(2)将赫兹弹性接触理论引入离散单元法建模,并考虑刀具的初始应力分布对裂纹扩展的影响,建立了包含刃形特性的双刃球齿滚刀侵入砂岩的离散元模型。通过对比分析得出了刀具侵入岩石时,刃形对岩土破碎特征的影响规律。
(3)在单把滚刀与岩石构成的系统中,岩石的跃进破碎特性及滚刀特有的蛇行现象,使得滚刀在切削过程中不可避免的发生振动。本文分别采用位移约束及力约束作为滚刀的下端边界条件,建立了适用于滚刀滚压硬、软岩和土壤的一般垂直振动微分方程,并对实验用滚刀进行了算例分析。
(4)在现有线切割试验台的基础上设计了双刃球齿滚刀侵入砂岩的观测试验。利用高速摄像仪成功捕捉到了岩石的崩裂现象,并巧妙地使用普通数码相机不连续地记录了密实核的形成过程,验证了相关结论。
(5)设计了实验用盘形滚刀,并在原有线切割试验台上进行切割混凝土的实验。观测到了混凝土的宏观破坏现象、获得了三向力的特征及岩石破碎块度的变化规律。
Recently, shield machine was widely used in many areas, such as construction of water conservancy and hydropower culverts, urban underground engineering and construction of artificial canal, underground tunnel, mine, mountain railway and highway tunnel. As one of the main cutters of shield machine in the cutterhead, disc cutter's cutting performance directly affects the excavation efficiency of shield machine. The paper comes from the topic "cutting mechanism of rock and theory of cutterhead design", which is the sub-project of the National Key Basic Research and Development Program of China (973 Program). The paper has attached great importance to rock-fragmentation characteristics and vertical cutting vibration, in order to improve structure design, tool life, adaptability of the cutter, optimize tool configuration in cutterhead and achieve the aims of 1 and lower energy consumption in tunnel excavation.
The paper complete contents as below:
1) Based on kinematics analysis of rock-fragmentation process of disc cutter, reasonably simplifying the problem, respectively building 2-D discrete element models of single cutter breaking rock with inclined joints, double cutters breaking rock without joints and with horizontal joints under the condition of single specific formation, the crack propagation of microcrack under different confined pressures, parameters of joints, cutter spacing and cutting orders was observed. Based on the propagation direction of crack and the formation rule of fragment,12 typical types of breaking modes while breaking rock by TBM cutters were concluded. Finally, the rock-fragmentation characteristics was analyzed in the respects of efficiency of breaking rock, the propagation ability of crack and rock broken lumpiness.
2) Considering the effects of initial stress distribution of the cutters on crack propagation, Hertz elastic contact theory was introduced into the simulation. A discrete finite element model indenting into sandstone by TBM double-edged spherical tooth hob was established. Comparing the simulation and literature results, the influence law of cutting edge shape on rock-fragmentation characteristics during breaking process was acquired.
3) In the vibration system consisting of a single disc cutter and rock, the cutter is inevitably quivering during the breaking process because of the characteristics of step-crushing and the snake-like phenomenon. The general differential equations of vertical vibration of disc cutter suitable for breaking hard rock, soft rock and soil were respectively established by adopting displacement constraint and force constraint as the lower boundary condition. Taking the disc cutter designed for experiments mentioned in this paper rolling granite as the example, the dynamic simulation analysis was done.
4) Based on the existing linear cutting test-bed, an observation experiment is designed, in which double-edged spherical tooth hob indents into sandstone. The phenomena of rock crushing and bursting were captured by the high speed camera successfully and the formation process of compacting rock core was discontinuously recorded by the general digital camera skillfully. The related theory derived from the simulation result was verified.
5) The experiment of the designed cutter rolling concrete was carried out on the test-bed. The macroscopical phenomenon of concrete-crushing was observed, the changing law of rock broken lumpiness and the characteristics of three-axis force were obtained.
引文
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