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<p>The cutter–rock frictional contact during the operation of a tunnel boring machine (TBM) can cause unavoidable changes in the cutterhead system load and violent vibrations, which are potential causes of abnormal damage accidents in TBMs. The factors that affect the cutterhead loading characteristics are complex and include the mechanical structure, rock breaking, and operating parameters. The lack of analysis in any of these aspects may result in incomplete reflection of the actual situation. In this study, a combined approach integrating particle flow discrete element method (DEM)–multi-body dynamics (MBD) is utilized to establish a dynamic connection between rock–cutter interaction and the vibrational behavior of the cutterhead–cutter system. This investigation examines the effects of rock mass properties, cutter design parameters, and cutterhead rotation rates on the force distribution characteristics and vibrational performance of the excavation system, including its working mechanisms. The analysis results indicate that increases in rock strength, cutterhead rotational speed, or penetration depth lead to higher energy consumption for rock crushing in a unit of time. Consequently, the cutter’s workload and the cutting force also increase. Serving as the dominant outer stimulus for the cutterhead–cutter assembly, enhanced rock penetration forces naturally lead to amplified oscillatory responses. The damping characteristics present in the rock–cutter interaction zone can significantly attenuate the cutter’s vibrational energy. The flat-top cutter has a larger touch surface and range of force relative to the circular-top cutter, resulting in a larger volume of the crushed zone and more rock powder. This leads to a stronger damping effect and effectively dissipates vibration energy, resulting in lower vibration intensity for the cutter with flat-top under equivalent loading conditions. The paper’s numerical method acquires rock-cutting data, load, and vibration from a unified model. The results are helpful to accurately evaluate the service state of TBM, and provide effective technical support for safe operation and maintenance.</p>

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Loading and Dynamic Character Analysis of TBM Cutterhead–Cutter System Considering Contact-Vibration Coupling

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Ruixue Sun,
  • Mengqi Zhang,
  • Zhiyao Zhang,
  • Longguan Zhang,
  • Jiliang Mo

摘要

The cutter–rock frictional contact during the operation of a tunnel boring machine (TBM) can cause unavoidable changes in the cutterhead system load and violent vibrations, which are potential causes of abnormal damage accidents in TBMs. The factors that affect the cutterhead loading characteristics are complex and include the mechanical structure, rock breaking, and operating parameters. The lack of analysis in any of these aspects may result in incomplete reflection of the actual situation. In this study, a combined approach integrating particle flow discrete element method (DEM)–multi-body dynamics (MBD) is utilized to establish a dynamic connection between rock–cutter interaction and the vibrational behavior of the cutterhead–cutter system. This investigation examines the effects of rock mass properties, cutter design parameters, and cutterhead rotation rates on the force distribution characteristics and vibrational performance of the excavation system, including its working mechanisms. The analysis results indicate that increases in rock strength, cutterhead rotational speed, or penetration depth lead to higher energy consumption for rock crushing in a unit of time. Consequently, the cutter’s workload and the cutting force also increase. Serving as the dominant outer stimulus for the cutterhead–cutter assembly, enhanced rock penetration forces naturally lead to amplified oscillatory responses. The damping characteristics present in the rock–cutter interaction zone can significantly attenuate the cutter’s vibrational energy. The flat-top cutter has a larger touch surface and range of force relative to the circular-top cutter, resulting in a larger volume of the crushed zone and more rock powder. This leads to a stronger damping effect and effectively dissipates vibration energy, resulting in lower vibration intensity for the cutter with flat-top under equivalent loading conditions. The paper’s numerical method acquires rock-cutting data, load, and vibration from a unified model. The results are helpful to accurately evaluate the service state of TBM, and provide effective technical support for safe operation and maintenance.