Analysis on the Rock–Cutter Interaction Mechanism During the TBM Tunneling Process

The accurate prediction of rock cutting forces of disc cutters is crucial for tunnel boring machine (TBM) design and construction. Disc cutter wear, which affects TBM penetration performance, has frequently been found at TBM sites. By considering the operating path and wear of the disc cutter, a new model is proposed for evaluating the cutting force and wear of the disc cutter in the tunneling process. The circular path adopted herein, which is the actual running path of the TBM disc cutter, shows that the lateral force of the disc cutter is asymmetric. The lateral forces on the sides of the disc cutter are clearly different. However, traditional solutions are obtained by assuming a linear path, where the later forces are viewed as equal. To simulate the interaction between the rock and disc cutter, a simple brittle damage model for rock mass is introduced here. Based on the explicit dynamic finite element method, the cutting force acting on the rock generated by a single disc cutter is simulated. It is shown that the lateral cutting force of the disc cutter strongly affects the wear extent of disc cutter. The wear mechanism is thus underestimated by the classical model, which was obtained by linear cutting tests. The simulation results are discussed and compared with other models, and these simulation results agree well with the results of present ones.