Abstract Disc cutter wear is the result of dynamic contact and friction between the tools and rocks in tunnel boring machine (TBM) tunneling. It can lead to a reduction in excavation efficiency, disruption of construction schedules, and extra costs. The geological indices, such as uniaxial compressive strength (UCS), Brazilian tensile strength (BTS) and Cerchar abrasion index (CAI), and the tunneling parameters, such as advance rate and rotation speed, were collected in the Shenzhen metro tunnel excavation project, and they have major effects on the cutter consumption rate. The wear data of 871 disc cutters over a 1592 m-long advance distance were analyzed. It was found that 87% of the disc cutters used were replaced due to normal wear, and the others were replaced due to abnormal wear. Flat wear mainly occurs for the disc cutters in the central area of the cutterhead, because they have a larger rotational resistance and eccentric loading due to their smaller rotational radius. The abnormal wear of the outer-area disc cutters mainly consists of forms of cutter ring cracking and bearing crushing owing to a higher rotation speed. A disc cutter wear prediction model was established to estimate the disc cutter consumption based on the plastic removal abrasiveness and motion analysis of the cutter rings. A rough linear correlation between the cumulative wear depth and the advance distance is found, and the wear rate varies during the tunneling progress due to the different geotechnical or construction parameters. The predicted wear is generally less than the actual wear, and the maximum prediction error is 49.4 mm. The predicted error is always larger for the disc cutters that have a high probability of non-uniform wear, especially for those in the outer area.

中文翻译：

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硬岩地层隧道掘进时TBM盘刀磨损分析与预测——以深圳某地铁隧道开挖为例

摘要 圆盘刀具磨损是隧道掘进机(TBM)掘进中工具与岩石之间动态接触和摩擦的结果。它可能导致挖掘效率降低、施工进度中断和额外成本。深圳地铁隧道开挖工程采集了单轴抗压强度（UCS）、巴西抗拉强度（BTS）、Cerchar磨损指数（CAI）等地质指标，以及掘进速度、转速等掘进参数，它们对刀具消耗率有重大影响。分析了 1592 m 长进给距离内 871 把盘形刀具的磨损数据。结果发现，所使用的盘式刀具87%是由于正常磨损而更换的，其余的则是由于异常磨损而更换的。平面磨损主要发生在刀盘中心区域的盘形刀具，因为它们的旋转半径较小，具有较大的旋转阻力和偏心载荷。外圆盘刀具的异常磨损主要表现为由于转速较高导致的刀环开裂和轴承压坏等形式。建立了圆盘刀具磨损预测模型，基于刀环的塑性去除磨蚀性和运动分析来估算圆盘刀具的消耗量。发现累积磨损深度和前进距离之间存在粗略的线性相关性，并且由于岩土或施工参数的不同，在隧道掘进过程中磨损率会发生变化。预测磨损一般小于实际磨损，最大预测误差为49.4mm。