• Geomechanics and Engineering
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• v.34 no.1
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• pp.103-113
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• 2023

This study focused on understanding the relationship between the design of a tunnel boring machine disc cutter ring and its rock-breaking efficiency, as well as the applicable conditions of different cutter ring types. The discrete element method was used to establish a numerical model of the rock-breaking process using disc cutters with different ring types to reveal the development of rock damage cracks and variation in cutter penetration load. The calculation results indicate that a sharp-edged (V-shaped) disc cutter penetrates a rock mass to a given depth with the lowest load, resulting in more intermediate cracks and few lateral cracks, which leads to difficulty in crack combination. Furthermore, the poor wear resistance of a conventional V-shaped cutter can lead to an exponential increase in the penetration load after cutter ring wear. In contrast, constant-cross-section (CCS) disc cutters have the highest quantity of crack extensions after penetrating rock, but also require the highest penetration loads. An arch-edged (U-shaped) disc cutter is more moderate than the aforementioned types with sufficient intermediate and lateral crack propagation after cutting into rock under a suitable penetration load. Additionally, we found that the cutter ring wedge angle and edge width heavily influence cutter rock-breaking efficiency and that a disc cutter with a 16 to 22 mm edge width and 20° to 30° wedge angle exhibits high performance. Compared to V-shaped and U-shaped cutters, the CCS cutter is more suitable for soft or medium-strength rocks, where the penetration load is relatively small. Additionally, two typical case studies were selected to verify that replacing a CCS cutter with a U-shaped or optimized V-shaped disc cutter can increase cutting efficiency when encountering hard rocks.

• Geomechanics and Engineering
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• v.35 no.6
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• pp.647-663
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• 2023

The investigation of the disc cutter wear prediction has an important guiding role in TBM equipment selection, project planning, and cost forecasting, especially when tunneling in a long-distance rock formations with high strength and high abrasivity. In this study, a comprehensive database of disc cutter wear data, geological properties, and tunneling parameters is obtained from a 1326 m excavated metro tunnel project in leptynite in Shenzhen, China. The failure forms and wear consumption of disc cutters on site are analyzed with emphasis. The results showed that 81% of disc cutters fail due to uniform wear, and other cutters are replaced owing to abnormal wear, especially flat wear of the cutter rings. In addition, it is found that there is a reasonable direct proportional relationship between the uniform wear rate (WR) and the installation radius (R), and the coefficient depends on geological characteristics and tunneling parameters. Thus, a preliminary prediction formula of the uniform wear rate, based on the installation radius of the cutterhead, was established. The correlation between some important geological properties (K_V and UCS) along with some tunneling parameters (F_n and p) and wear rate was discussed using regression analysis methods, and several prediction models for uniform wear rate were developed. Compared with a single variable, the multivariable model shows better prediction ability, and 89% of WR can be accurately estimated. The prediction model has reliability and provides a practical tool for wear prediction of disc cutter under similar hard rock projects with similar geological conditions.

• Journal of Korean Tunnelling and Underground Space Association
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• v.18 no.2
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• pp.143-154
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• 2016

This study investigated the occurrences, causes, and mitigation of the recent ground subsidence and underground cavity generation events in Korea. Two main causes of ground subsidence are (1) the soil erosion by seepage during tunneling and earth excavation and (2) the damage of underground pipes. The main cause of the soil erosion during tunneling was the uncontrolled groundwater flow. Especially, when excavating soft grounds using a tunnel boring machine (TBM), the ground near TBM operation halt points were found to be the most vulnerable to failure. The damage of underground pipes was mainly caused by poor construction, material deterioration, and differential settlement in soft soils. The ground subsidence during tunneling and earth excavation can be managed by monitoring the outflow of groundwater and eroded soils in construction sites. It is expected that the ground subsidence by the underground pipe damage can be managed or mitigated by life cycle analysis and maintenance of the buried pipes, and by controlling the earth pressure distribution or increasing the bearing capacity at the upper ground of the buried pipes.

• Tunnel and Underground Space
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• v.23 no.5
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• pp.428-441
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• 2013

Nowadays, a roadheader as a mechanical excavator is in high demand, especially for mines under various conditions and tunnels where TBMs are inapplicable. However, the records of roadheaders in Korea are seldom reported. Moreover, the number of countries with their intrinsic design and manufacturing technologies of roadheaders is very limited. Therefore, this study aimed to analyse the excavation principles of roadheader as well as its key design parameters for its optimized selection and design. In addition, the database with 143 world-widely collected roadheader design data was built, and a few statistical correlations were derived from it. A schematic procedure for roadheader design based on the database was also proposed.

• Tunnel and Underground Space
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• v.29 no.2
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• pp.124-134
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• 2019

Subcritical crack growth in rock material can occur under monotonic and cyclic loading. Subcritical crack growth plays an important role in evaluating the long-term stability of structures in rocks. This paper presents the results of studies conducted to determine subcritical crack growth parameters under monotonic and cyclic loading in rock-like material. The constant stress rate method was employed for monotonic loading. The subcritical crack growth parameter of n under cyclic loading was determined by the relation between the rate of crack growth per cycle and stress intensity factor range. The specimens contained pre-existing flaws with 45 and 60 degrees of inclination angle and flaws spacing and continuity were varied to arrange crack growth in shear or tensile manner. The results show that the parameter of n is almost constant regardless of the applied load conditions such as monotonic and cyclic or shear and tension.

• Journal of Korean Tunnelling and Underground Space Association
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• v.20 no.2
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• pp.255-268
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• 2018

Subsea tunnel can be highly vulnerable to seawater intrusion due to unexpected high-water pressure during construction. An artificial ground freezing (AGF) will be a promising alternative to conventional reinforcement or water-tightening technology under high-water pressure conditions. In this study, the freezing energy and required time was calculated by the theoretical model of the heat flow to estimate the total amount of refrigerant required for the artificial ground freezing. A lab-scale freezing chamber was devised to investigate changes in the thermal and mechanical properties of sandy soil corresponding to the variation of the salinity and water pressure. The freezing time was measured with different conditions during the chamber freezing tests. Its validity was evaluated by comparing the results between the freezing chamber experiment and the numerical analysis. In particular, the freezing time showed no significant difference between the theoretical model and the numerical analysis. The amount of refrigerant for artificial ground freezing was estimated from the numerical analysis and the freezing efficiency obtained from the chamber test. In addition, the energy ratio for maintaining frozen status was calculated by the proposed formula. It is believed that the energy ratio for freezing will depend on the depth of rock cover in the subsea tunnels and the water temperature on the sea floor.

• Journal of Korean Tunnelling and Underground Space Association
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• v.17 no.4
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• pp.473-485
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• 2015

The problems for non-rotating of a disc cutter proceed from the faults in inner parts of the disc cutter such as the leak of hydraulic fluid, the intrusion of tunnel mucks and water, overloading, overheating, poor assembly and substandard material. The rotating of a disc cutter is an indicator to show that the inner parts of disc cutter is operable, although the rotational torque depends on the extent of the damage. Therefore, the key in the problems for non-rotating of disc cutter is to maintain that the tapered roller bearings are working properly. This study aims to investigate the inner parts disassembled from disc cutters applied to the field tests in order to help decision for reuse of the disc cutters. As results, surface finishing to remove the scratch on the load zone of the hubs is needed, with the intent to reuse a hub. And the investigation of lapping surface by optical microscope of floating seals and the contamination test of oil need to be performed for reuse of a disc cutter. Especially, the analysis results show that the floating seals play a key role in the normal operation of bearings. There is nothing significant to report in the rest parts such as bearing, shaft, seal retainers.