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<p>This study investigates the tribological behavior of tunnel boring machine (TBM) disc cutters through a full-scale disc abrasion test (FDAT) program, with a focus on quantifying the effects of rock properties and operating conditions on specific cutter wear loss (SCWL). Tests were performed on two rock types, argillaceous shale (CAI = 0.4, UCS = 22.8&#xa0;MPa) and quarzitic marble (CAI = 2.4, UCS = 33.1&#xa0;MPa), using single- and double-edge cutters from three manufacturers (types A, B, and C). The results show that SCWL correlates strongly with the rock abrasivity and compressive strength as well as the applied normal and rolling forces, with the marble producing considerably higher wear. However, simple bivariate correlations fail to capture the combined influence of these factors. An empirical multi-parameter wear model of the form SCWL = <i>f</i>(CAI, UCS, <i>F</i><sub>n</sub>, <i>F</i><sub>r</sub>, cutter type factor) was developed. The analysis indicates that rock properties determine the baseline wear rate, which is subsequently amplified by operational forces. Cutter geometry (single vs. double edge) and type modulate the wear response by altering the load distribution and wear resistance. The proposed framework provides a quantitative basis for predicting TBM cutter life under diverse geological and operational conditions. From an engineering perspective, such predictive capability supports more reliable cutter life planning, reduces the risk of cutter and cutterhead damage, and helps minimize downtime-related costs in TBM tunneling projects.</p>

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Full-Scale Experimental Study on TBM Disc Cutter Wear: Influence of Rock Type and Operating Conditions

  • 期刊论文

  • 发表日期：

    2026年4月28日

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  • R. Nikbakht Nasrabadi,
  • E. Farrokh,
  • P. Maarefvand

摘要

This study investigates the tribological behavior of tunnel boring machine (TBM) disc cutters through a full-scale disc abrasion test (FDAT) program, with a focus on quantifying the effects of rock properties and operating conditions on specific cutter wear loss (SCWL). Tests were performed on two rock types, argillaceous shale (CAI = 0.4, UCS = 22.8 MPa) and quarzitic marble (CAI = 2.4, UCS = 33.1 MPa), using single- and double-edge cutters from three manufacturers (types A, B, and C). The results show that SCWL correlates strongly with the rock abrasivity and compressive strength as well as the applied normal and rolling forces, with the marble producing considerably higher wear. However, simple bivariate correlations fail to capture the combined influence of these factors. An empirical multi-parameter wear model of the form SCWL = f(CAI, UCS, Fn, Fr, cutter type factor) was developed. The analysis indicates that rock properties determine the baseline wear rate, which is subsequently amplified by operational forces. Cutter geometry (single vs. double edge) and type modulate the wear response by altering the load distribution and wear resistance. The proposed framework provides a quantitative basis for predicting TBM cutter life under diverse geological and operational conditions. From an engineering perspective, such predictive capability supports more reliable cutter life planning, reduces the risk of cutter and cutterhead damage, and helps minimize downtime-related costs in TBM tunneling projects.