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<p>The accuracy of disc cutter force in rock-breaking processes hinges on the rationality of the rock failure mode. This force crucially determines the validity of predicted results for disc cutter life (DCL). However, the traditional finite element method (FEM) falls short in simulating the transfer phenomenon in the dense core rock beneath disc cutter tips. To address this issue, a combination of the FEM and smooth particle hydrodynamics (SPH) were used to simulate the rock-breaking process. The results demonstrate that determining the transformation threshold between FEM and SPH by replicating classical mechanical experiments is appropriate. This method effectively captures the transformation process of the dense core rock beneath the disc cutter tips, yielding numerical results comparable to measured and analytical outcomes. The relative sliding distance value between the disc cutter and rock can be determined by numerical model parameters. This value, when combined with energy analysis theory, facilitates the prediction of disc cutter wear. The deviations between predicted and tested results are no more than 10%. The calculation models and research findings presented in this paper offer new insights into the study of TBM disc cutter life.</p>

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TBM Disc Cutter Life Prediction Using the FEM-SPH Coupled Method: A Case Study

  • 期刊论文

  • 发表日期：

    2025年4月29日

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  • Huijian Zhang,
  • Boyi Fu,
  • Qiaoyu Wang,
  • Lichuan Wang,
  • Jianwei Wang,
  • Yongwang Jiang,
  • Jianfeng Qi

摘要

The accuracy of disc cutter force in rock-breaking processes hinges on the rationality of the rock failure mode. This force crucially determines the validity of predicted results for disc cutter life (DCL). However, the traditional finite element method (FEM) falls short in simulating the transfer phenomenon in the dense core rock beneath disc cutter tips. To address this issue, a combination of the FEM and smooth particle hydrodynamics (SPH) were used to simulate the rock-breaking process. The results demonstrate that determining the transformation threshold between FEM and SPH by replicating classical mechanical experiments is appropriate. This method effectively captures the transformation process of the dense core rock beneath the disc cutter tips, yielding numerical results comparable to measured and analytical outcomes. The relative sliding distance value between the disc cutter and rock can be determined by numerical model parameters. This value, when combined with energy analysis theory, facilitates the prediction of disc cutter wear. The deviations between predicted and tested results are no more than 10%. The calculation models and research findings presented in this paper offer new insights into the study of TBM disc cutter life.