Cutting Wheel Opening Configuration in Soft Ground Shield Tunneling by Considering Field and Numerical Studies

Mohammadi, Dariush; Shahriar, Kourosh; Moarefvand, Parviz; Farrokh, Ebrahim

doi:10.22044/jme.2024.14323.2678

Document Type : Original Research Paper

Authors

¹ Department of Mining Engineering, Amirkabir University of Technology, Tehran, Iran

² Department of Mining Engineering, Amirkabir university of Technology, Tehran, Iran

https://doi.org/10.22044/jme.2024.14323.2678

Abstract

The correct design of the cutterhead of a tunnel boring machine (TBM) plays a vital role in the efficient operation of the machine, as the cutterhead structure remains unchanged during the tunneling project. This paper aims to elucidate the fundamental principles in the design of the cutterhead opening in soft ground based on data obtained from TBM manufacturers. Initially, a comprehensive database of soft ground cutterheads from different TBM manufacturers across various projects and ground conditions was compiled. The most frequently used cutterhead configurations with diameters exceeding 5 meters were categorized into 36 distinct opening configurations based on a radial opening ratio curve and opening patterns per sector. Next, the performance parameters and particle flow characteristics of three Herrenknecht cutterhead designs featuring varying opening configurations in the central and circumference areas were analyzed using the Discrete Element Method (DEM) by considering material parameters for machine and soil and contact parameters between soil particles and soil particles-machine structures. Hertz–Mindlin model was assigned as the contact model for these elements. Additionally, three different cutterheads employed in Tehran metro projects in Iran were identified by monitoring the cutterhead torque and thrust force under same geotechnical conditions and operational parameters. Generally, a higher opening percentage in the central area of the cutterhead indicates good performance during excavation in cohesive soils. However, the higher opening percentage in circumferential areas is a better choice for effective excavated material removal around the cutterhead and tunnel in non-cohesive soils, weathered rocks, mixed and heterogeneous conditions.

Keywords

Main Subjects

Mechanized Excavation

References

[1]. Mohammadi, D., Shahriar, K., Moarefvand, P., & Farrokh, E. (2023). Discussion of cutterhead opening design for earth pressure balance machines (EPBMs) in soft grounds. Proceedings of the Institution of Civil Engineers (ICE) - Geotechnical Engineering.

[2]. Nishitake, S. (1987). Earth pressure balanced shield machine to cope with boulders. Rapid Excavation and Tunneling Conference, pp. 552–572.

[3]. Burger, W. (2007). Design Principles for Soft Ground Cutterheads, Rapid Excavation and Tunneling Conference, pp. 13–22.

[4]. Mongillo, G., & Alsaleh, M. (2011). Discrete element method to predict soft ground cutterhead performance, Society for Mining, Metallurgy, and Exploration, pp. 1058–1067.

[5]. Grothen, B. (2015). Optimizing Soft Ground Excavation: Development and Design of EPB and Slurry Cutterheads, ITA WTC.

[6]. Herrenknecht, M., Thewes, M., & Budach, C. (2011). The development of earth pressure shields: from the beginning to the present, Geomechanics and Tunnelling (4), pp. 11-35.

[7]. Rostami, J., & Chang, S. (2017). A closer look at the Design of Cutterheads for Hard rock Tunnel-Boring Machines, Engineering (3), pp. 892–904.

[8]. Wu, L., Guan, T., & Lei, L., (2013). Discrete element model for performance analysis of cutterhead excavation system of EPB machine, Tunnelling and Underground Space Technology (37), pp. 37–44.

[9]. British Tunnelling Society (BTS) (2005). Closed-face tunnelling machines and ground stability, ICE publisher.

[10]. Yang, H.J., Fu, D.M., & Ge, X.R. (2006). Experimental study and numerical simulation of earth pressure around shield machine. Yanshilixue Yu Gongcheng Xuebao 25, 1652–1657.

[11]. Ocak, I., & Bilgin, N. (2009). The performance of Two EPB machines in Istanbul Metro tunnel drives in soft and shallow ground, a Chapter in ResearchGate.

[12]. Shi, H., Yang, H., Gong, G., & Wang, L. (2011). Determination of the cutterhead torque for EPB shield tunneling machine, Automation in construction (20), pp. 1087-1095.

[13]. Wang, L., Gong, G., Shi, H., & Yang, H. (2012). Modeling and analysis of thrust force for EPB shield tunneling machine, Automation in construction (27), pp. 138-146.

[14]. Guo, W., Hu, J., & Liu, J. (2014). The scheme design for the earth pressure balance shield cutterhead structure, Engineering Mechanics, pp. 4589-4599.

[15]. Godinez, R., Yu, H., Mooney, M., Alavi-Gharahbagh, E., & Frank, G. (2015). Earth Pressure Balance Machine Cutterhead Torque Modeling: Learning from Machine Data, Colorado School of Mines.

[16]. Sandell, T.D., & Stypulkowski, J. (2015). Dual mode “crossover” type tunnel boring machines: a unique solution for mixed ground in the middle east, robbinstbm.com.

[17]. Cheng, C., Liao, S., Chen, L., & Zhou, Z. (2016). Comparative Study on Suitability of EPB Machine in Typical Sandy Cobble Ground in China, Transportation Research Congress, pp. 590-603.

[18]. Li, X., Yuan, D., & Huang, Q. (2017). Cutterhead and Cutting Tools Configurations in Coarse Grain Soils, The Open Construction and Building Technology Journal (11), pp. 182-199.

[19]. Yang, Z.H., Jiang, Y.S., & Zhang, J.X. (2018). Radial opening ratio of EPB TBM cutterheads. Chinese Journal of Geotechnical Engineering, Vol. 40, No. 12.

[20]. Ebrahimy, B., Khosravi, A.A., Lees, D., & Koohsari, A. (2022). Effect of cutterhead on performance of EPBM in mixed face condition, WTC2022, Copenhagen, Denmark.

[21]. Chen, X.J., Fang, P.P., Chen, Q.N., Hu, J., Yao, K., & Liu, Y. (2023). Influence of cutterhead opening ratio on soil arching effect and face stability during tunnelling through non-uniform soils, underground space journal.

[22]. Sarfarazi, V., Haeri, H., Fatehi Marji, M., & Saeedi, G. (2024). On the 2D discrete element analyses of the transversely isotropic elastic geo-materials; insight to scale effects and loading rate, Journal of Mining and Environment 15 (3), 1051-1070.

[23]. Sarfarazi, V., Haeri, H., Bagheri, F., Zarrin Ghalam, E., & Fatehi Marji, M. (2022). PFC simulation of Brazilian tensile strength test in geomaterials’ specimens with T-shaped non-persistent joints, Journal of Mining and Environment 13 (4), 1189-1209.

[24]. Fu, J., Safaei M.R., Haeri, H., Sarfarazi, V., Fatehi Marji, M., Xu, L., & Arefnia, A. (2022). Experimental investigation on deformation behavior of circular underground opening in hard soil using a 3D physical model, Journal of Mining and Environment 13 (3), 727-749.

[25]. Sarfarazi, V., & Asgari, K. (2022). Influence of Single Tunnel and Twin Tunnel on Collapse Pattern and Maximum Ground Movement, Journal of Mining and Environment 13 (1), 117-128

[26]. Sarfarazi, V., Haeri H., Shemirani, A.B., Hedayat, A., & 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 Journal 20 (4), 429-437.

[28]. Cundall, P.A., & Strack, O.D.L. (1979). A discrete numerical method for granular assemblies. Geotechnique 29 (1), 47–65.

[27]. DEM Solutions Ltd. (2022). EDEM user guide. Edinburgh, United Kingdom.

[29]. Hu, G.M. (2010). Analysis and simulation of granular system by discrete element method. Wuhan University of Technology Press, Wuhan (in Chinese).

[30]. Ma, T. (2016). Study on particle flow and ground settlement control of earth pressure balance shield tunneling in sandy pebble stratum based on the DEM. Master thesis. Jiaotong University, Beijing, pp. 46 (in Chinese).

[31]. EFNARC A. (2005). Speciﬁcations and Guidelines for the use of specialist products for mechanized tunnelling (TBM) in soft ground and hard rock. Recomm Eur Fed Prod Contract Spec Prod Struct 1:18–30.

[32]. ASTM D 3080 (2011). Standard test methods for direct shear test of soils under consolidated drained conditions. ASTM International, West Conshohocken, PA, USA.

[33]. P.O.R. Consulting Co. (2009). Geotechnical Investigations & Foundation Report for Tunnel and Station, Tehran Metro Line 6 and 7 Project., Tehran, Iran (in Persian).

[34]. DIN EN 12350-2 (2019). Testing fresh concrete - Part 2: Slump test; German version EN 12350-2. Prüfung von Frischbeton - Teil 2: Setzmaß; Deutsche Fassung EN 12350-2.

[35]. SELI Co. (2015). Earth Pressure Balance Machine Specification and the Operational Parameters and Performance Analysis. Report for Tehran Metro Project-Line 6 and 7 North–South Section, Tehran, Iran.

Cutting Wheel Opening Configuration in Soft Ground Shield Tunneling by Considering Field and Numerical Studies

References

References

Volume 16, Issue 1January 2025Pages 321-351

Volume 16, Issue 1
January 2025
Pages 321-351