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Study of the cutter-rock interaction mechanism during TBM tunnelling in mudstone: insight from DEM simulations of rotatory cutting tests

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Abstract

The rock breaking mechanism plays a significant role in TBM (tunnel boring machine) performance prediction, which has not yet been understood satisfactorily. In this work, a series of rotary cutting simulations via a particle-based DEM (discrete element method) for mudstone were conducted to explore the rock breaking mechanism and cutter-rock interaction during TBM tunnelling. Different cutting scenarios were considered. The rock breaking events were inferred from the breakage of bonds between particles constituting the mudstone. The spatial distribution of microcracks was obtained in the form of bond breaks between particles. The cracking features of mudstone are different from those reported for hard rocks. The characteristics of the contact stress distribution were also analysed and fitted by a combined Hertz-Weibull model. The distribution ranges of bond breaks and cutter-rock contact stress are both positively related to the penetration depth but not largely dependent on the cutting radius. However, the side force has a negative relationship with the cutting radius, and this dependency is more significant with increasing penetration depth. The bond-break distribution is skewed to the outer side of the cutter due to different cutting trajectories and centrifugal effects. Moreover, the bonds tend to break towards the existing cutting groove due to the release of radial confinement. The variation in cutting forces interrelates with the bond breakage events, which reduces the local stiffness and strength of the rock. The existence of the former cutting groove yields eases rock breakage and associated smaller cutting forces.

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Funding

The research was supported by the National Natural Science Foundation of China (Grant Nos. 41672262 & 52008307). The third author would like to acknowledge the funding by the China Postdoctoral Science Foundation (Grant No. 2021T140517).

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Authors and Affiliations

  1. Department of Geotechnical Engineering, College of Civil Engineering, Tongji University, Shanghai, 200092, China

    Miaoyuan Tang, Xin Huang & Shuaifeng Wang

  2. State Key Laboratory of Geotechnical Engineering, Ministry of Education, Tongji University, Shanghai, 200092, China

    Miaoyuan Tang, Xin Huang & Shuaifeng Wang

  3. Shanghai Tunnel Engineering Co. Ltd., Shanghai, 200082, China

    Yixin Zhai, Qianwei Zhuang & Chi Zhang

  4. Shanghai Shield Design and Experimental Research Center Co. Ltd., Shanghai, 200137, China

    Yixin Zhai, Qianwei Zhuang & Chi Zhang

Authors
  1. Miaoyuan Tang
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  2. Xin Huang
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  3. Shuaifeng Wang
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  4. Yixin Zhai
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  5. Qianwei Zhuang
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  6. Chi Zhang
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Contributions

Miaoyuan Tang: data curation, formal analysis, writing–original draft. Xin Huang: supervision, methodology, funding acquisition. Shuaifeng Wang: funding acquisition, formal analysis, writing–review and editing. Yixin Zhai: project administration. Qianwei Zhuang: project administration. Chi Zhang: investigation.

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Correspondence to Shuaifeng Wang or Qianwei Zhuang.

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Highlights

• DEM simulations were established to investigate the cutter-rock interaction mechanism

• Different cutting parameters and scenarios are considered in the rotary cutting tests

• The cracking features of soft mudstone under a cutter are different from hard rocks

• The variation in cutting forces interrelates with the rock breakage events

• Cutter-rock contact stress distribution is fitted by a combined Hertz-Weibull model

Appendix Supplementary

Appendix Supplementary

Fig. 35
figure 35

Vertical distribution of the portion of horizontally dominated bond-breaks in single cutting cases

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Fig. 36
figure 36

Proportion of horizontally dominated bond-breaks (inclination angle less than 45°) as a function of the ratio of depth to penetration in single cutting cases (r = 350 mm)

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Tang, M., Huang, X., Wang, S. et al. Study of the cutter-rock interaction mechanism during TBM tunnelling in mudstone: insight from DEM simulations of rotatory cutting tests. Bull Eng Geol Environ 81, 298 (2022). https://doi.org/10.1007/s10064-022-02785-x

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