Document Type : Original Research Paper

Authors

Faculty of mining engineering, Sahand University of Technology, Tabriz, Iran

Abstract

This study is an attempt to design and manufacture a tunnel boring machine (TBM) simulator to better understand the interaction between soil and cutting tools, due to the lack of an accepted method for this issue. In this paper, Sahand Soil Abrasion Test (SSAT) is introduced, which is built by the Sahand University of Technology. The experimental and real results of tool wear are presented. The results firstly demonstrate that the cutting tools wear in the coarse-grained soils can be less than in the fine-grained ones in the real conditions. However, in the soils with fine grains higher than 10%, the wear of cuttings tools increase in the laboratory condition when grading parameters increase. In soils with fine grains less than 10%, the wear of tools decreases by increasing the grading parameters. Also the results reveal that the coefficient of gradation depend on the amount of silt and clay in the soil samples. The investigations show that sorting is another good criterion for investigating the power of soil abrasively. Furthermore, it indicates that the cutting tools wear increases when the moisture content of the soil structure in the dense condition approaches the optimal moisture content. Finally, the results indicate that the wear and torque of the cutterhead could be reduced by 58% and 34%, respectively, when the excavated materials have the appropriate conditioning.

Keywords

Main Subjects

[1]. Zum Gahr K., H. (1987). Microstructure and wear of materials (Vol. 10).  Elsevier, Rotterdam.
[2]. Stolarski, T. A. (2000). Tribology in machine design. Butterworth – Heinemann, Oxford, 298.
[3]. Verhoef, P. N. W. (1997). Wear of rock cutting tools. Balkema, Rotterdam, 327.
[4]. Nilsen B., Dahl F., Holzhauser, J., and Raleigh P. (2007b). Abrasivity of soils in TBM tunneling. Tunnels Tunneling International, 36–38.
[5]. Moammeri, H. and Tarigh Azali, S. (2010). Taking Abrasive Action. World Tunneling, 24–27.
[6]. Tarigh Azali, S. and Moammeri, H. (2012). EPB-TBM tunneling in abrasive ground, Esfahan Metro Line 1. In: Phienwej, N., Boonyatee, T. (Eds.), ITA-AITES World Tunnel Congress (WTC), Bangkok, Thailand.
[7]. Köhler, M., Maidl, U., and Martak, L. (2011). Abrasiveness and tool wear in shield tunneling in soil. Geomechanik und Tunnelbau, 36–53.
[8]. Amoun, S., Sharifzadeh, M., Shahriar, K., Rostami, J., and Tarigh Azali, S. (2017). Evaluation of tool wear in EPB tunneling of Tehran Metro, Line 7 Expansion. Tunneling and Underground Space Technology 61, 233–246.
[9]. Ansari, T., Chakeri, H., Darbor, M., Amoun, S., and Shakeri, H. (2023). Investigating the effect of soil grading parameters on the tool wear in mechanized tunneling using EPB-TBM machine. Journal of Mining and Environment, Articles in Press, Accepted Manuscript, Available Online from 30 September.
[10]. Nickjouye Tabrizi, AH., Chakeri, H., Darbor, M., Amoun, S. and Shakeri, H. (2023). Evaluating the effect of tool wear in soft soil using new TBM tunneling simulator device. Journal of Testing and Evaluation, 51(6).
[11]. Mousapour, H., Chakeri, H., Darbor, M., and Hekmatnejad, A. (2023). Evaluating the wear of cutting tools using a tunnel boring machine laboratory simulator. Mining of Mineral Deposits, 17(2), 28-34.
[12]. Khoshzaher, E., Chakeri, H., Darbor, M., and Shakeri, H. (2023). The effects of water content and grain size on the clogging and abrasivity of fine-grained soils in mechanized excavation. Rudarsko-geološko-naftni zbornik, 38(2), 65-74.
[13]. Haeri, H., Marji, M. F., and Shahriar, K. (2015). Simulating the effect of disc erosion in TBM disc cutters by a semi-infinite DDM. Arabian Journal of Geosciences8, 3915-3927.
[14]. Sarfarazi, V., Haeri, H., Shemirani, A. B., Hedayat, A., and Hosseini, S. S. (2017). Investigation of ratio of TBM disc spacing to penetration depth in rocks with different tensile strengths using PFC2D. Computers and Concrete, An International Journal20(4), 429-437.
[15]. Haeri, H. and Marji, M.F. (2016). Simulating the crack propagation and cracks coalescence underneath TBM disc cutters. Arabian Journal of Geosciences 9, 124.
[16]. Haeri, H., Marji, M.F. and Shahriar, K. (2015). Simulating the effect of disc erosion in TBM disc cutters by a semi-infinite DDM. Arabian Journal of Geosciences 8, 3915–3927.
[17]. Gökhan, K and Şener, A. (2016). Geological Investigation and Excavability Classification of a Multi-Layer Clay Quarry. International Black Sea Mining & Tunnelling Symposium, 336-344.
[18]. KÜLEKÇİ, G. (2022). The Relation of the Method used in Tunneling Operations with the Geological Structure Example of the Black Sea Coastal Road. Journal of Civil Engineering and Construction 11 (4), 255-263.
[19]. KÜLEKÇİ, G. (2022). The Relation of the Method used in Tunneling Operations with the Geological Structure Example of the Black Sea Coastal Road. Journal of Civil Engineering and Construction 11 (4), 255-263.
[20]. Külekçi, G., Vural, A., and Aliyazıcıoğlu, Ş. (2022). Assessment of excavability classification in a Limestone Quarry: A case study from Bayburt, Turkey. Iranian Journal of Earth Sciences 14 (4), 241-251.
[21]. Zhang, Y. Y., Sun, Z., Huang, P., Li, Y. Q., Chen, Q., and Fu, S. Y. (2021). Experimental and numerical investigations of wear behaviors of short-carbon-fiber reinforced polyetherimide composite. Composite Structures270, 114057.
[22]. Farrokh, E. and Kim, D. Y. (2018). A discussion on hard rock TBM cutter wear and cutterhead intervention interval length evaluation. Tunnelling and Underground Space Technology81, 336-357.
[23]. Dai, Sh., DaiHe, Xu., Tong, Ch., Gao, F., Zhang, Sh., and Sheng, D. (2023). Stability of sandy soils against internal erosion under cyclic loading and quantitatively examination of the composition and origin of eroded particles. Canadian Geotechnical Journal, 9.
[24]. Macias, J., Dahl, F., and Bruland, A. (2016). The Rolling Indentation Abrasion Test (RIAT)- NTNU/SINTEF's new approach to tool life assessments on hard rock tunnel boring. Tunnelling journal, cutter research.
[25]. LCPC (1990). LCPC Abrasivemeter Standard. Normalisation Francaise, 18–579.
[26]. Alavi Gharahbagh, E., Rostami, J., and Palomino, A.M. (2011). New soil abrasion testing method for soft ground tunneling applications. Tunneling and Underground Space Technology Journal 26 (5), 604–613.
[27]. Rostami, J., Alavi Gharahbagh, E., Palomino, A.M., and Mosleh, M. (2012). Development of soil abrasivity testing for soft ground tunneling using shield machines. Tunneling and Underground Space Technology Journal (28), 245–256.
[28]. Barzegari, G., Uromeihy, A., and Zhao, J. (2013). A newly developed soil abrasion testing method for tunneling using shield machines. Quarterly Journal of Engineering Geology and Hydrogeology 46, 63–74.
[29]. Jakobsen, P.D. and Lohne, J. (2013). Challenges of methods and approaches for estimating soil abrasivity in soft ground TBM tunneling. Wear 308 (1–2), 166–173.
[30]. Wei, Y., Yang, Y., and Tao, M. (2018). Effects of gravel content and particle size on abrasivity of sandy gravel mixtures. Engineering geology, 26-35.
[31]. Wei, Y., Zheng, X., Su, F., Li, M., Li, F., and Yang, U. (2018). Evaluating of cutting tool wear of earth pressure balance shield in granular soil based on laboratory test. Testing and evaluation, 927-941.
[32]. Wei, Y., Yang, U., Tao, M., Wang, D., and Jie, Y. (2020). Earth pressure balance shield tunnel in sandy gravel deposits: a case study of applications of soil conditioning. Engineering geology and environment, 5013-5030.
[33]. Mohsen M., Rostami J., and Alavi Gharahbagh E. (2012). Effects of relative hardness and moisture on tool wear in soil excavation operations. Wear, 302, 1555–1559.
[34]. Rostami J., Alavi G. E., Talebi K., and Mosleh M. (2013). Study of Tool Wear in Soft Ground Mechanized Tunneling by using a New Soil Abrasion Testing System. Available on web.
[35]. Alavi Gharahbagh E. (2013). Development of a new soil abrasion test and analysis of impact of soil properties on tool wear for soft ground mechanized tunnelling. (PhD Thesis), the Pennsylvania State University.
[36]. Alavi Gharahbagh E., Rostami J., and Talebi K. (2014). Experimental study of the effect of conditioning on abrasive wear and torque requirement of full face tunneling machines. Tunnelling and Underground Space Technology, 41, 127–136.
[37]. Kupferle, J., Rottger, A., Theisen, W., and Alber, M. (2016). The RUB Tunneling Device–A newly developed test method to analyze and determine the wear of excavation tools in soils. Tunneling and Underground Space Technology, 1-6.
[38]. Thuro K., Singer J., Kasling H., and Bauer M. (2006). Soil abrasivity assessment using the LCPC testing device. Felsbau, Vol. 24, 37-45.
[39]. Nilsen B., Dahl F., Holzhauser J., and Raleigh P. (2007a). New test methodology for estimating the abrasiveness of soils for TBM tunneling. RETC Proceedings, 104–116.
[40]. Bruland A. (1998). Hard rock tunnel boring: Drillability test methods. Project report 13A-98, NTNU Trondheim.
[41]. Kasling H. and Thuro K. (2010). Determining abrasivity of rock and soil in the laboratory. Available on Web.
[42]. Thuro K. and Kasling H. (2009). Classification of the abrasiveness of soil and rock. Geomechanics and Tunnelling 2, No. 2, 179–188.
[43]. Jakobsen P. D., Bruland A., and Dahl F. (2013). Review and assessment of the NTNU/SINTEF Soil Abrasion Test (SAT™) for determination of abrasiveness of soil and soft ground. Tunnelling and Underground Space Technology, 37, 107–114.
[44]. Nilsen, B., Dahl, F., Holzhäuser, J., Raleigh, P. (2006c). SAT: NTNU’s new soil abrasion test. Tunnels & Tunnelling International, 43–45.
[45]. Rogers C. A., B. C. Lane, S. A. Senior. (2003). The Micro-Deval Abrasion Test for Coarse and Fine Aggregate in Asphalt Pavement. International Center for Aggregates Research 11th Annual Symposium, Austin, TX.
[46]. Hunt, E. (2001). Micro-Deval coarse aggregate test evaluation. Oregon Department of Transportation ODOTRep. OR-RD-01-13 Final Report, Salem, Ore.
[47]. Rostami J., Ozdemir L., Bruland A., and Dahl F. (2005). Review of issues related to Cerchar Abrasivity testing and their implications on geotechnical investigations and cutter cost estimates. RETC proceeding.
[48]. ASTM G75-01 (2001). Standard Test Method for determination of slurry abrasivity (Miller number) and slurry abrasion response of materials (SAR number).
[49]. Nilsen B., Dahl F., Holzhäuser J., and Raleigh P. (2006). Abrasivity testing for rock and soils. Tunnels & Tunnelling International.
[50]. American Association of State Highway and Transportation Officials, (1999). Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine. 96.
[51]. Gudbjartsson J.T. and Iversen, K. (2003). High-quality wear-resistant paving blocks in Iceland. Proc. 7th International Conference. in Concrete Block Paving, Sun City 12th– 15th.
[52]. American Association of State Highway and Transportation Officials, (1999). Standard Test Method for Resistance of Coarse Aggregate to Degradation by Abrasion in the Micro Deval Apparatus. TP 58-00.
[53]. Senior S. A., C. A. Rogers (1991). Laboratory Tests for Predicting Coarse Aggregate Performance in Ontario. Transportation Research Record, No. 1301, 97-106.
[54]. Plinninger R. J., Spaun G., and Thuro K. (2002a). Prediction and classification of tool wear in drilling and blasting tunneling. Proceedings of  9th congress of the International Association for Engineering Geology and the Environment, Durban, South Africa, 2226-2236.
[55]. Plinninger R. J. and Restner U. (2008). Abrasiveness Testing, Quo vadis? - A Commented Overview of Abrasiveness Testing Methods. Geomechanik und tunnelbau1.
[56]. Thuro K. (1996). Drillability prediction– geological influences in hard rock drill and blast tunneling.  Geol Rundsch, 426-437.
[57]. Amoun, S., Sharifzadeh, M., Shahriar, K., and Rostami, J. (2015). Soil abrasiveness for EPB-TBM along Tehran metro tunnel line 7, Iran. In SEE Tunnel: Promoting Tunneling in South East European Region: 41st General Assembly and World Tunnel Congress of International Tunneling and Underground Space Association ITA-AITES. 22-28.
[58]. ASTM D422-63 (2007). Standard test method for particle-size analysis of soils (With drawn 2016). ASTM International, West Conshohocken, PA.
[59]. Thuro, K., Singer, J., Käsling, H., and Bauer, M.  (2007). Determining abrasivity with the LCPC test. In:  Proceedings of the 1st Canada – U.S. Rock Mechanics Symposium, ARMA-07-103. 
[60]. Plinninger, R., Käsling, H., Thuro, K., and Spau, G. (2003). Testing conditions and geo-mechanical properties influencing the CERCHAR abrasiveness index (CAI) value. International Journal Rock Mechanics Mining Sciences 40 (2), 259–263.
[61]. Das, B. M. and Sobhan, K. (2002). Principles of geotechnical engineering, USA. Eds. Brooks/Cole-Thomson Learning Inc.
[62]. Hashemnejad, H., Ghafoori, M., Lashkaripour, G.R., and Tariq, A.S. (2012). Effect of geological parameters on soil Abrasivity using LCPC machine for predicting LAC. International Journal of Emerging Technology and Advanced Engineering (2), 71–75.
[63]. Hashemnejad, A., Ghafoori, M., and Tarigh, A.S. (2016). Utilizing water, mineralogy and sedimentary properties to predict LCPC abrasivity coefficient. Bulletin of Engineering Geology and the Environment 75, 841–851.
[64]. EFNARC. (2005). Specification and Guidelines for the Use of Specialist Products in Mechanized Tunneling (TBM) in Soft Ground and Hard Rock. Farnham, UK.