Determination of the cutterhead torque for EPB shield tunneling machine

Cutterhead torque is an important parameter for the design and operation of earth pressure balance (EPB) shields. Based on the analysis of several completed project cases from job sites, the conventional torque determination model based on experimentation proves rough enough to be improved. Composition and corresponding calculation method of cutterhead torque are presented, taking into account of cutterhead structure, cutting principle and the interaction between cutterhead and soil. Considering a Φ1.8 m EPB test machine in the lab, theoretical calculation following the improved model and test are carried out with three typical types of soils. Calculation and test results indicate that the cutterhead torque varies with geological conditions apparently, and the opening ratio of the cutterhead as well as earth pressure turns out to be the two most important factors in determining the cutterhead torque. The test results also show that the torque calculation formula for EPB shield tunneling can reasonably predict the excavation torque required by the cutterhead in clay soil tunneling, but for cohesionless tunneling, soil conditioning reduces the amount of torque necessary.     

Development of the Soft Ground Abrasion Tester (SGAT) to predict TBM tool wear,torque and thrust

The Norwegian University of Science and Technology (NTNU), SINTEF Rock Engineering and BASF Construction Chemicals have jointly developed a new test device called the Soft Ground Abrasion Tester (SGAT). The ambition and purpose of the design of the test and the applied test procedure is to replicate an in situ soil – TBM excavation tool contact, in a small and simplified scale. The current development is attempting to bridge a gap when it comes to estimating soft ground and soil abrasivity, as earlier research on e.g. the NTNU/SINTEF Soil Abrasion Test™ (SAT) shows that it does not catch up all driving factors for soft ground and soil abrasivity directly. The paper summarizes the development of the SGAT apparatus, and shows its capabilities to evaluate, quantify and compare how the soil mineralogy, water content, pressure, compaction, and the use of soil conditioning additives influences the wear rate on the SGAT excavation tool. During testing the required torque and thrust are monitored and logged, making it possible to measure various soil–soil conditioning matrixes requirement for operational parameters.     

Discrete element model for performance analysis of cutterhead excavation system of EPB machine

With the aim of probing for design theory of cutterhead excavation system of earth pressure balance (EPB) machine, the parameters representing the system performance are concluded firstly. Then a 3D model for cutterhead excavation system of EPB machine is presented with the discrete element method (DEM) software PFC^3D, which is capable of simulating the tunneling ground in site, the machine structure and the excavation operation. The performance parameters indicating stability of excavation face, soil discharging rate, cutterhead system torque and cutter wear are measured by running the DEM code. The results obtained with the DEM model are accord with situ data. It indicates that the DEM model is a promising method replacing the field experiment to analyze the influences of the structural parameters on system performances, which are essential for structure optimization design of the cutterhead system of EPB machine.     

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。     

广州地区软硬复合地层盾构施工技术研究

基于广州地区典型软硬复合地层条件下的盾构掘进工程实践,分析研究了盾构掘进过程中存在的刀盘刀具磨损、姿态难控制、结泥饼和喷涌等施工风险,从盾构选型、刀具配置与管理、掘进参数控制、盾构姿态控制、渣土改良与同步注浆及信息监测与反馈等方面采取应对措施,并以广州地铁二号线越～三区间盾构隧道施工为例进行说明.     

上软下硬地层盾构机滚刀磨损特性研究

以广州地铁某盾构区间为工程背景,结合上软下硬地层的强度特性,提出了硬地层所占面积与掌子面面积之比来评估上软下硬地层中地层分布情况的方法,确定硬地层对开挖面强度特性的影响。根据地层特性和分布情况,提出了适应不同均一地层的刀盘合理转速以及适用于上软下硬地层的刀盘设计转速。通过监测盾构机掘进过程中的刀盘扭矩变化,提出根据刀盘扭矩变化幅度制定刀盘转速调整时机的预警机制,实现刀盘转速提前调整。结合实际应用效果,上软下硬地层会使盾构滚刀产生过快磨损,超前调整刀盘转速可有效降低滚刀受冲击荷载的影响,延长滚刀正常工作时的掘进距离,显著提高上软下硬地层中盾构施工效率。     

Examining the influence of TBM-ground interaction on electrical resistivity imaging ahead of the TBM

Tunnel excavation by means of tunnel boring machines (TBMs) is susceptible to unknown changes ahead of the tunnel face. Geophysics offers a technique called electrical resistivity that can continuously, in real-time, spatially map the formation in front of the TBM. Electrical resistivity has been successfully established for many applications including vadoze zone hydrology, oil/gas location, mineral location and failure detection in geo-structures. Yet it has not been well-established for TBM excavations. This is in part due to the complexity of the TBM tunneling environment and the uncertain influence this environment may have on the success of TBM-integrated-electrical resistivity to predict changes ahead of the tunnel face. One significant uncertainty lies in the interface region that exists around the TBM created during the modification of the virgin formation by a mechanical mixing action of the rotating cutterhead and the injection of additives used to aid in the extraction of the muck and protect the cutting tools from frictional wear. In this study, we investigate the influence of this interface region on TBM-integrated-electrical resistivity for both hard rock and soft ground tunneling conditions through finite element modeling. Regarding the performance of TBM-integrated-electrical resistivity to detect changes ahead of the cutting face, the interface region holds significant influence for both earth pressure balance (EPB) and open mode tunneling conditions. Electrical resistivity for slurry based tunneling is not influenced by the interface region. Simulations suggest that TBM-integrated-electrical resistivity can be sensitive to a formation change that is located up to five diameters in front of the TBM.     

New soil abrasion testing method for soft ground tunneling applications

Prediction of the tool wear and life, as well as secondary wear on machine components, in soft ground tunneling using shielded machines with a pressurized face has been a difficult task due to the lack of a universally accepted measurement system for soil abrasion. While some existing abrasion tests have been adopted in recent years to measure soil abrasion, these systems have inherent mismatches with the actual working conditions at the tunnel face. This paper reviews some of the background studies in this area and introduces the initial steps towards the development of a new soil abrasion testing system. The design and operational parameters for a proposed device that is under development for measuring a soil abrasion index are discussed and the preliminary results of testing on various soil samples are presented.     

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。     

砂性土层盾构掘进面前土体改良现场试验

针对土压平衡盾构在砂性土层掘进时常面临的闭塞、喷涌、刀具严重磨损、掘进速度过慢及刀盘扭矩过大等难题,依托上海某盾构在高含砂率砂性土层中掘进的工程实例,在盾构掘进面前方掺加肥皂水、泡沫剂进行现场试验,通过试验前后盾构施工参数的反馈分析结果,确定出土体改良最佳方案。将试验成果应用于相似地层,通过长距离改良前后掘进速度、刀盘扭矩以及刀具磨损变化来检验试验成果。研究结果表明:肥皂水改良效果不明显,泡沫剂改良效果优于肥皂水,适量浓度泡沫剂能大幅度提高掘进速度、降低刀盘扭矩和减少刀具损耗。     

软土地层土压平衡盾构法施工的模型试验研究

我国沿海地区以及许多内陆城市的地下广泛分布着很深的软黏土沉积层,目前该区域的许多城市都已兴建或正在筹建地铁。为确保在这种软弱地层中能采取与之相适应的盾构工法、减少对周围环境的影响以及降低工程造价,以上海地铁M8线某区间隧道工程为研究背景,采用室内模型试验的方法,进行了土压平衡盾构针对软土地层的适应性试验研究。为此,首先根据相似理论和模型试验方法建立了土体–盾构机器之间的相似系统;随后,针对上海地区特定的软土地层,进行了人工模型土壤的配制和模型试验方法的设计,并利用直径400 mm的模型盾构机模拟直径6340 mm的原型盾构机;最后,进行盾构不同工作参数组合的掘削试验,并记录下试验过程中机器工作参数及土体内应力和变形变化的有关试验结果,通过对试验数据的整理与分析,得出了软土地层中土压平衡盾构法施工的一些有用的规律。     

考虑渣土特征的盾构施工力学动态耦合仿真研究

土压平衡盾构渣土作为开挖面支护力与土仓压力之间的传递介质,其力学性能直接影响到土仓压力的控制、开挖面支护力大小和地层变形等。通过编制离散元和有限差分耦合程序,模拟了土压平衡盾构机动态掘进过程,分析了渣土改良对土仓压力传递性和开挖面地层响应的影响。研究结果表明:盾构掘进过程中土仓压力会出现一定的波动幅度,越靠近刀盘,压力的波动幅度越大。刀盘转动角度对土仓压力有一定的影响。刀盘面板转至监测点水平线上时土压力较大,刀盘开口转至监测点水平线上时土压力较小。渣土改良能增大土仓压力传递系数,降低土仓压力的离散性。压力传递系数不是一个稳定值,而是一个受刀盘转动角度影响的变化值。     

基于长短时记忆网络的盾构机刀盘扭矩实时预测

盾构机是土质隧道开挖的优质工程机械,被广泛应用在地铁建设。刀盘扭矩是保证盾构正常推进的关键参数,能被精确实时预测对预防灾难事故、确保施工正常推进具有极高的指导意义。针对现有扭矩预测多为计算平均值的问题,提出一种基于长短时记忆(Long-Short Term Memory,LSTM)网络的扭矩实时预测模型。首先通过分析盾构机状态参数与扭矩的相关性,选择一组关键状态参数,降低输入维度;然后建立LSTM扭矩预测模型;最后利用该模型在归一化后的实际数据集上进行验证并与BP网络模型对比。试验结果表明,该模型在测试集上均方差为0.002 81,平均绝对误差为0.036 7,均优于BP网络;该模型具有良好的预测能力与泛化性能,能够很好地拟合关键状态参数与刀盘扭矩之间的非线性关系。     

Theoretical model of the equivalent elastic modulus of a cobblestone–soil matrix for TBM tunneling

Cobblestone–soil mixed ground is a composite comprising cobblestones surrounded by soil. It is typical mixed-face ground encountered during tunnel boring machine (TBM) tunneling, and it may result in cutter wear, jamming of the roller cutterhead, poor TBM performance and cost overruns. The present paper investigates the deformation problem of cobblestone–soil mixed-face ground during TBM excavation. The ground under study is composed of two components (soil matrix and cobblestones) usually firmly bonded together at the interface, and can be regarded as a continuum. Previous studies have proposed many theoretical models for a composite material with two components. Representative models include the parallel model, series model, and effective medium theory model. Nonetheless, these models are limited by their assumptions and preconditions. In the present study, under an assumption of uniform strain, analytical solutions were derived for the equivalent elastic modulus while the cobblestone is assumed to be perfectly spherical or ellipsoidal. Triaxial compression tests were carried out to validate the analytical solutions. The equivalent elastic modulus derived from the triaxial experiments and theoretical models matched rather closely. The analytical solutions are helpful in clarifying the deformation of such ground and enhancing TBM performance.     

Experimental study on working parameters of earth pressure balance shield machine tunneling in soft ground

Deep sedimentary deposits of soft clays are widely distributed in coastal areas as well as many interior major cities in China. In order to study the stratum adaptability of earth pressure balance (EPB) shield machine tunneling in such types of soft ground, model tests of tunneling excavation, using the running tunnel of the Shanghai Metro Line M8 as a background, are carried out with different over burden ratios, opening rates of cutter head, driving speeds and rotation speeds of screw conveyor. Based on the test results, the interrelationships between chamber pressure and mucking efficiency, mucking rate and driving speed, thrust force and torque are obtained. The influences of tunnel depth, opening rate of cutter head and driving speed on thrust force and torque are revealed. Such findings can not only facilitate establishing relationships between shield working parameters and soil properties, but also serve as a guide for the design and construction of shield tunnel in soft ground.     

富水砂层土压平衡盾构关键施工技术

沈阳地铁二号线会展中心站一世纪广场站隧道盾构区间穿越中粗砂、砾砂层,砂性土层内摩擦角大,碴土流动性差,排土困难,地下水量丰富、水压高,因此盾构掘进控制困难,容易造成地表沉降.从土压平衡盾构的适应性、刀盘和螺旋输送机的结构、刀具的配置和加固、碴土改良措施、沉降控制方法等方面介绍土压平衡盾构穿越砂层的施工技术.在施工过程中,通过采取同步注浆、二次注浆、加强施工监测等措施保证了既有线行车安全.     

复合地层中盾构刀具磨损超前控制研究

通过分析国内土压平衡式盾构隧道典型工程案例,对上软下硬地层近年来的施工问题和采取的主要措施统计分析,总结出土压平衡盾构在上软下硬地层中施工关键问题及其规律.结合地层特性,针对滚刀磨损问题,提出评估上软下硬地层分布情况及盾构施工地质适应性问题的方法;同时,对盾构机掘进过程中的盾构推力、刀盘扭矩、贯入度变化监测统计,通过比...     

An experimental study on cutting tool hardness optimization for shield TBMs during dense fine silty sand ground tunneling

Bulletin of Engineering Geology and the Environment - The estimation of soil abrasivity and cutting tool wear during soft ground tunneling is complicated and arduous work due to the lack of a...     

Physical modeling of tunnels in soft ground: A review

Physical modeling has played an important role in studies related to excavation of tunnels in soft ground. A variety of modeling techniques have been developed by researchers all over the world to study ground response to tunneling. These techniques range from the two-dimensional trap door tests to the miniature tunnel boring machines that simulate the process of tunnel excavation and lining installation in a centrifuge. This paper presents a review of selected physical models that have been developed and used in soft ground tunneling research. Furthermore, this paper discusses some of the various approaches used to record soil deformation and failure mechanisms induced by tunneling. Experimental setups and sample results are presented for each technique as described by original authors. A summary of the advantages and disadvantages of each method is also presented.     

Laboratory model tests and field investigations of EPB shield machine tunnelling in soft ground in Shanghai

In the last decades, many studies have been presented by different scholars on the environmental problems induced by the shield tunnelling in soft ground. But it mainly concentrated on ground surface settlement, tunnel surface stability and the influence to existing structures. Among them, little attention was paid to soil disturbance caused by the mismatch of machine’s operation parameters. In order to reveal this inherent relation, a series of laboratory model tests were carried out in the 1/16 scale for a field tunnel in practice where the tunnel had 6.4 m diameter. The tests to simulate earth pressure balance (EPB) shield tunnelling in soft ground were conducted with a microshield machine (0.4 m diameter). Measurements were carried out simultaneously in each test for total jack thrust force, cutting torque, chamber pressure, mucking ratio, ground surface displacement, and earth pressure. Based on the analysis of test results under different overburden ratio, cutterhead aperture ratio and screw rotation speed, the relationships between machine’s operation parameters themselves and its influence on disturbance to surrounding soil mass were discovered. Such discoveries were also verified by the field investigations. These results are useful for engineers and technicians to select suitable and serviceable machine operation parameters and reduce environmental influence at all stages of tunnel construction.