Design and performance evaluation of a novel cutter-ring material based on TBM rock-breaking mechanisms.

Abstract

Tunnel boring machine (TBM) disc cutters face significant challenges in complex geological conditions, particularly in composite sandstone-mudstone strata, where low rock-breaking efficiency and excessive wear affect construction efficiency and safety. To address these issues, this study first developed a cutter-rock contact model using ABAQUS, simulating stress distribution, crack propagation, and mechanical characteristics during the rock-breaking process. The simulation results confirmed the feasibility of the model, showing that stress concentration plays a key role in crack propagation, with the normal force dominating the rock-breaking process, while the rolling force acts as an auxiliary. Building on these findings, a novel cutter ring material was developed using plasma cladding technology to significantly enhance its wear resistance and impact toughness. Experimental results indicate that the new cutter ring material extends the cutter's service life by over 20%, significantly improving TBM efficiency by reducing cutter replacement frequency and maintenance costs. This research provides critical insights into cutter selection and optimization, offering a theoretical basis for improving tunneling efficiency and extending the operational lifespan of TBM cutters. The findings contribute to both theoretical advancements and practical applications in the field of tunnel boring.