复杂岩石地层隧道掘进机操作特性分析

为提高掘进效率,改进掘进机与地层的匹配性设计,对掘进机的操作特性进行研究。基于重庆越江隧道盾构掘进试验,分析复杂岩石地层盾构刀盘扭矩、刀盘推力及转速的参数选用原则,在此基础上,分析主掘进参数与切深的关系。随后,对不同地层条件下刀盘扭矩与推力之间的匹配性进行分析,绘制了刀盘扭矩与推力之间的操作特性曲线,并用于分析和制定不同地层条件下的主掘进参数匹配方案。对于较软的泥岩,刀盘扭矩先达到最大值,而推力却不能发挥其最大能力;岩石强度增高,所需推力增加,在发挥扭矩能力的前提下,推力也能发挥其功能,从而使二者达到最佳操作关系;若岩石强度过高,推力保持在最大值,但切深很浅,滚刀旋转阻力减小,刀盘扭矩很难发挥最大能力。因此,应视地层软硬,根据刀盘推力与扭矩的操作特性对刀盘的主掘进参数进行合理设计,并在掘进过程中实时调整其匹配关系。     

Predicting performance of EPB TBMs by using a stochastic model implemented into a deterministic model

The current study is an attempt to address the stochastic nature of the rock excavation process by suggesting a stochastic performance prediction model implemented into a deterministic model developed for hard rock TBMs. Full-scale linear cutting experiments using constant cross-section and V-type of disc cutters are performed on two different limestone samples to provide the basic input required for the deterministic model used for estimation of instantaneous penetration rate, daily advance rate, thrust and torque requirements of TBMs. Stochastic estimation is performed by using a Monte Carlo simulation program by applying iterations to implement the probabilistic distribution of each model parameter and provide knowledge of a confidence level. Results of the suggested model are verified by measuring the field performance of two earth pressure balance (EPB) TBMs excavating competent rocks in semi-closed mode. The results indicate that the suggested model works well for prediction of instantaneous cutting/penetration rate for both TBMs and both types of disc cutters. However, an improvement on the model is required for estimation of cutterhead torque and thrust of EPB TBMs. The stochastic model implemented into the deterministic model results in almost similar predictions with the deterministic model in 50% (best guess) probability. However, the stochastic modeling provides a tool for exploring the full implications of linear cutting experiments and allows assessing the probability of occurrence and predicting variations of the TBM performance parameters, covering the uncertainties/risks.     

引洮单护盾TBM前盾改造分析

结合甘肃省引洮供水一期工程实践,针对单护盾TBM施工过程中遇到的饱水疏松砂岩特点,探讨了TBM的前盾改造问题,通过对几种前伸护盾方案进行比较及相关计算,得出了TBM的前盾改造能控制刀盘扭矩,减少出渣量的结论。     

Disc cutter wear prediction for a hard rock TBM cutterhead based on energy analysis

Disc cutter wear is a crucial problem that influences the working efficiency and security of hard rock tunnel boring machines (TBMs). This wear results from friction energy accumulation and conversion. In this study, the process of hard rock TBM disc cutter wear is identified and analyzed by quantifying the collective energy change. This study starts with an analysis of the friction process between the disc cutter and hard rock. The relationship between the rolling force work and thrust force work of the disc cutter is examined. As a result, the disc cutter energy equation is determined, and the meaning of the upper and lower bounds of this equation are discussed. Based on the above results, the hard rock TBM cutterhead energy equation is then deduced. A method to identify the friction work is developed. According to the energy wear theory, the cutter wear law on hard rock for a TBM cutterhead is revealed, and a method for predicting disc cutter wear for a hard rock TBM cutterhead is advanced. Furthermore, the validity of this prediction method is confirmed by utilizing data from project cases.     

Double shield TBM performance analysis in difficult ground conditions: a case study in the Gerede water tunnel,Turkey

The performance analysis of double shield TBMs in difficult ground conditions in the Gerede tunnel is presented in this study. The strength of the encountered formations along the tunnel route varied from medium strength (sandstone, limestone) to high strength (basalt). The total length of tunnels is 31.6 km, which was excavated by three double shield TBMs having diameter of 5.57 m. Literature studies are first carried out in order to review the difficult ground conditions and their impacts on mechanized tunnelling. Later, the project, geology, and the characteristics of the TBMs are given in detail. Then the factors affecting the performance of the TBMs, machine utilization, and operational parameters (torque, thrust) are discussed in detail. In the light of these facts, the main objective of this study is to describe the possible improvement methods to reduce the effect of these difficulties on TBM performance.     

盾构刀盘扭矩对风化岩地基中邻近桩基的影响

基于地铁盾构施工对邻近某客运站桩基影响的问题,利用FLAC^3D有限元模拟分析软件,通过八种工况对比分析了刀盘扭矩与盾构推力对风化岩地基中邻近桩基的影响。结果表明:刀盘扭矩与盾构推力对桩基的影响呈现不同的规律。刀盘扭矩对桩基的影响规律主要为:盾构刀盘扭矩的存在使得桩身主要产生沿隧道横向的附加弯矩和位移,桩身沿隧道纵向的附加弯矩和位移相对较小;桩身最大弯矩和最大水平位移均发生在隧道中心线附近。与刀盘扭矩的影响不同,盾构推力主要使桩身产生沿隧道纵向的附加弯矩和位移;但桩身最大弯矩和最大水平位移也发生在隧道中心线附近。在风化岩地基中,刀盘扭矩对桩基沿隧道横向的影响是不可忽略的。     

Thrust force requirements for TBMs in squeezing ground

Rapidly converging ground may exert such a high pressure on the shield that the thrust force is no longer sufficient to overcome shield skin friction and the TBM becomes jammed. This paper advances a number of theory-based decision aids, which will support rapid, initial assessments to be made of thrust force requirements. A comprehensive parametric study has been carried out using the finite element method and, based on the numerical results, dimensionless design nomograms have been worked out that cover the relevant range of material constants, in situ stress and TBM characteristics. The nomograms make it possible to assess the feasibility of a TBM drive in a given geotechnical situation and to evaluate potential design measures or operational measures such as reductions in shield length, the installation of a higher thrust force, increases in the overcut or the lubrication of the shield surface, thus making a valuable contribution to the decision-making process.     

Realtime prediction of hard rock TBM advance rate using temporal convolutional network (TCN) with tunnel construction big data

Real-time dynamic adjustment of the tunnel bore machine (TBM) advance rate according to the rock-machine interaction parameters is of great significance to the adaptability of TBM and its efficiency in construction. This paper proposes a real-time predictive model of TBM advance rate using the temporal convolutional network (TCN), based on TBM construction big data. The prediction model was built using an experimental database, containing 235 data sets, established from the construction data from the Jilin Water-Diversion Tunnel Project in China. The TBM operating parameters, including total thrust, cutterhead rotation, cutterhead torque and penetration rate, are selected as the input parameters of the model. The TCN model is found outperforming the recurrent neural network (RNN) and long short-term memory (LSTM) model in predicting the TBM advance rate with much smaller values of mean absolute percentage error than the latter two. The penetration rate and cutterhead torque of the current moment have significant influence on the TBM advance rate of the next moment. On the contrary, the influence of the cutterhead rotation and total thrust is moderate. The work provides a new concept of real-time prediction of the TBM performance for highly efficient tunnel construction.     

An appraisal of TBM performances in Turkey in difficult ground conditions and some recommendations

The geology of Turkey is very complex and major Northern and Eastern Faults including minor faults associated to these faults create tremendous problems, like squeezing of the TBM, excessive water ingress, TBM face collapses, as encountered in the Kargi power tunnel, the Dogancay energy tunnel, the Gerede water tunnel, and the Nur Dagi railway tunnel. Mixed ground conditions with ophiolites, graphitic schists and melanges with boulders are other fundamental difficulties leading to squeezing and blocking of the TBMs or even causing complete failures of the segments and abandoning of the tunnel. A typical example for tunnel abandoning is the Kosekoy high speed tunnel and an example for excessive TBM squeezing is the Uluabat energy tunnel. The affects of dykes in the Istanbul region is known well by practicing tunnel engineers. These andesitic rocks, make fractures in the country rock and cause several problems during TBM excavation like blocking the cutterhead and excessive disc cutter consumption. Typical examples are the Goztepe-Kadıkoy Metro tunnels, and the Melen water tunnel. The Beykoz utility tunnel is one of the most difficult tunnelling projects in Istanbul. Presence of clay minerals existing within the geologic formations is also one of the main reasons clogging the cutterhead of TBM as encountered in the Suruc water project. The effects of complex geology on the excavation efficiencies of different type of TBM’s used in the ten projects mentioned above are explained in this paper and some recommendations with a ground classification system for proper use of TBMs in faultyzones are given.     

盾构直接切削大直径桩基的掘削参数研究

以苏州地铁盾构切削14根大直径桥梁群桩工程为依托,通过理论分析和开展盾构切削Φ1200钢筋混凝土桩基现场试验,系统研究掘削参数的变化特征和影响因素,并提出相应的掘削参数设置与控制方案。研究表明：刀盘切桩乃非全断面切削,实际切桩刀数呈现显著的波动性,是推力、扭矩变化特征的主控因素;推力、扭矩平均值与桩身宽度成线性正比相关,与桩基偏移距离总体呈反比减小趋势;由于切桩时推速、推力、扭矩均波动较大,盾构应增配小流量低速推进泵;作用于桩身的纯切桩推力、纯切桩扭矩仍近似与刀盘切深成线性正比关系。实践表明：在合理掘削参数下,盾构连续切削多根钢筋混凝土桩基是可行的。     

Correlation of rock cutting tests with field performance of a TBM in a highly fractured rock formation: A case study in Kozyatagi-Kadikoy metro tunnel,Turkey

This paper presents and discusses detailed field and laboratory studies concerning boreability prediction of tunnel boring machines (TBMs) used in Kozyatagi-Kadikoy metro tunnels in Istanbul in a highly fractured rock formation. The determination of some design parameters and performance prediction of a tunnel boring machine (TBM) are carried out using full-scale rock cutting test. The intact rock samples having minimum sizes of 1.0 × 0.7 × 0.7 m are obtained from shale and limestone (Kartal Formation) along the tunnel line. The rock samples are subjected to full-scale laboratory rock cutting tests with different depth of cut and cutter spacing values using a constant cross section (CCS) disc cutter of 330 mm in diameter. Cutter forces, i.e., thrust force, rolling force and specific energy values are recorded for each cut. The results of the tests are first used to calculate TBM design and performance parameters such as torque and thrust requirements and cutting rates. In the second part of the research, the field performance of the TBM is recorded with the aid of data acquisition system installed within TBM and the predicted performance and design values obtained from full-scale rock cutting tests are compared with the field values. It is observed that fractured characteristics of the rock formation affect tremendously TBM performance and predicted values differ from the field data in some extend. It is believed that the results will serve as a guide for efficient selection and use of TBMs.     

Performance prediction of hard rock Tunnel Boring Machines (TBMs) in difficult ground

Performance prediction of TBMs is an essential part of project scheduling and cost estimation. This process involves a good understanding of the complexities in the site geology, machine specification, and site management. Various approaches have been used over the years to estimate TBM performance in a given ground condition, many of them were successful and within an acceptable range, while some missing the actual machine performance by a notable margin. Experience shows that the best approach for TBM performance prediction is to use various models to examine the range of estimated machine penetration and advance rates and choose a rate that best represents the working conditions that is closest to the setting of the model used for the estimation. This allows the engineers to avoid surprises and to identify the parameters that could dominate machine performance in each case. This paper reviews the existing models for performance prediction of TBMs and some of the ongoing research on developing better models for improved accuracy of performance estimate and increasing TBM utilization.     

Correlation of tunnel convergence with TBM operational parameters and chip size in the Ghomroud tunnel, Iran

Evaluating the impact of rock mass properties on a tunneling operation is crucial, especially when using a tunnel boring machine (TBM). It is an integral part of machine selection and performance prediction in the design and bidding stage. Monitoring and analysis of ground conditions during the construction is also essential to allow the operator to take precautionary measures in adverse geological conditions. This involves adjusting TBM operational parameters such as machine thrust and penetration to avoid potential problems caused by face collapse or excessive convergence and subsequent machine seizure that can cause long delays. Tunnel wall convergence is a function of rock mass characteristics, in situ stresses, size of excavation, and rate of penetration (ROP). It is one of the main factors in determining the use of shielded machines in deep rock tunnel projects. The case study of the Ghomroud water conveyance tunnel project, under construction by a double shield TBM, is used to examine the effect of rock mass parameters on tunnel convergence and hence on the need for over excavation and shield lubrication to avoid problems such as shield seizure. Results of a preliminary analysis of field observations show that the amount of the tunnel convergence can have a direct relationship with the percentage of powder and large rock fragments in the muck. In addition, tunnel convergence has shown a strong relationship with the TBM thrust/torque and rate of penetration (ROP). These relationships have been examined and the results of the analysis as well as the resulting formulas will be explained in this paper.     

盾构施工过程中的土体变形研究

 基于盾构施工过程,利用弹性力学Mindlin解,通过坐标变换经积分推导刀盘与土体之间摩擦力所引起的地面变形计算公式,并得到盾构施工引起的总地面变形计算公式。结合杭州地铁一号线工程中具有代表性的粉砂土层,分析盾构与土体的复杂相互作用,并对盾构与土体相互作用引起的土体变形特征进行计算。通过计算发现,盾构施工中盾壳摩擦和正面推力是盾构推力设置的主要因素,而刀盘与土体摩擦是刀盘扭矩设置的主要因素,盾构前方土体隆起主要由盾壳摩擦引起,刀盘摩擦作用主要引起地表沉降的非对称分布,地表沉降主要由盾尾空隙产生。通过实例计算并与实测结果对比发现,使用盾构变形计算公式适用范围在盾构机头前后±2L距离处,对指导实际盾构施工具有重要意义。     

Prediction of thrust and torque requirements of TBMs with fuzzy logic models

For successful tunnel excavations, selection of proper tunnel boring machine (TBM), optimization of design parameters and prediction of their performance are critical. Normal and rolling forces of disc cutters are used for determination of thrust, torque and power requirement of TBMs as well as prediction of their performance. Much research has been conducted to predict these parameters of disc cutters using analytical, empirical and numerical approaches. In recent years alternative methods, such as fuzzy logic, have been extensively used to deal with subjects having ambiguities and uncertainties. A model was established to predict normal forces of constant cross section (CCS) disc cutters in the rock cutting process by using fuzzy logic method. The other model which predicts specific energy requirement of disc cutter can also be used for predicting the rolling forces of these cutters. These models are based on experience and verified the database which consists of linear cutting test results generated at the Earth Mechanics Institute of the Colorado School of Mines. The models predict forces of disc cutters using uniaxial compressive and tensile strength of rocks, disc diameter and tip width, penetration and spacing of cuts.     

深部高应力隧道TBM护盾长度和推力计算方法研究

岩石隧道掘进机(TBM)法开挖长隧道是一种安全、快速、有效的隧道开挖方法,但TBM复杂高应力隧道掘进时易发生卡机事故,因此,TBM在设计之初应尽可能考虑地质环境的影响,降低TBM的卡机风险。通过分析高应力常规地层和高应力软弱破碎地层对TBM的影响,提出了高应力常规地层和高应力软弱破碎地层TBM卡机的两个判据。根据两个判据提出了考虑围岩力学参数的高应力隧道TBM护盾长度设计和推力设计理论计算方法,并给出了参数选取依据。最后依据西南地区某高应力隧道的实际围岩地质参数,计算分析了现有TBM设计的合理性。本研究可为TBM的盾体长度和推力设计计算提供围岩力学参数依据。     

Mechanical performance of TBM cutterhead in mixed rock ground conditions

The mechanical performance of TBM cutterhead including thrust, torque, eccentric force and overturning moment was calculated and analysed in different mixed rock ground conditions. The calculation model was built by identifying the rock type under each cutter using a ray intersection algorithm and calculating the cutting forces of each cutter using the CSM model. The mixed rock ground conditions were simplified as rock type distribution and rock strength classification. In the present paper, the rock distributions of the Layer-Banded Rock (LBR) and Random-Distributed Rock (RDR) types were considered. The influences of rock strength (Uniaxial Compressive Strength: UCS, Brazilian Tensile Strength: BTS), rock locations and number of rock layers were studied. For verification, a boring experiment was designed and conducted using an experimental cutterhead with 14 disc cutters. The rock box was poured with concrete C20, C40 and C60 layer by layer to prepare the LBR condition. The average torque and thrust of the calculation model and experiment were in good agreement. Some conclusions were drawn from the study on the rock strength, rock locations, area percentages of different rock layers and number of rock layers. And hence, some suggestions were proposed to enhance the tunnelling efficiency and reduce damage to the cutterhead.     

高地应力作用下大理岩岩体的TBM掘进试验研究

滚刀破岩效率的研究主要集中在室内线性试验机破岩试验和数值分析2个方面,在工地开展TBM掘进试验尚不普遍。锦屏二级水电站采用3台TBM开挖隧道群,3台TBM在不同洞深(不同地应力)条件对大理岩岩体进行TBM掘进试验、岩石渣片筛分试验及大渣片统计分析,研究岩体条件、TBM机器参数、TBM运行参数对TBM掘进速度的影响及高地应力作用下岩体可掘性指数的变化。研究结果表明:在高地应力条件下,尽管TBM掘进速度随推力增加而增大,但推力超过一定值后,TBM并不在优化状态下运行,TBM的运行需与岩体条件及地应力条件相匹配。     

Periodic inspection of gauge cutter wear on EPB TBMs using cone penetration testing

Cutterhead maintenance is usually required when the gauge cutters (over-cutters) wear down to the shield diameter. In soft ground pressurized shielded TBMs, inspection of gauge cutters usually involves complete stoppage of the operation. This can be a dangerous, costly, and time consuming process. In this study, a novel approach has been developed to monitor gauge cutter wear by considering the relationship between the overcut length and the length of the gauge cutters. By using the proposed testing system, frequent monitoring of gauge cutter length is possible at appropriate intervals during ring builds or maintenance without the need to enter the harsh environment of the excavation chamber. This monitoring system was used within an EPB TBM during the excavation of the University Link Light Rail Tunnel (U230) in Seattle, WA.     

济南复合地层土压平衡盾构掘进效能实测分析#br#

依托济南轨道交通一号线复合地层土压平衡盾构掘进施工,提出一种在盾构机额定配置条件下的分项功耗和施工参数离散性指标双结合的掘进效能评价方法,并据此分析得到刀盘切削、盾构推进和螺机出土效能的变化特征。结果表明：①土压平衡盾构穿越济南复合地层时,盾构掘进总功耗在400~1250kW变化,其中,刀盘切削和盾构推进是盾构掘进功耗的主要组成部分,占总功耗的66%~84%;②刀盘切削的扭矩和转速具有明显的聚集特征,而盾构推进速度和推力分布形态的聚集特征弱于刀盘参数;③螺机出土的转速和扭矩在不同地层中的差异性不大,螺机参数的聚集特征不明显;④由于盾构掘进的分项功耗与其离散性指标不存在必然的联系,盾构施工中可能存在掘进功耗小但施工控制困难的情况,应在盾构选型及施工过程中予以充分考虑。