全断面岩石掘进机刀盘振动机理研究

Vibration is the essential ingredient that influences life and reliability of metal structure, as well as emergence and accumulation of parasitic power, and even results in the failure of welding or structure. This project focuses on the study of vibration of TBM cutterhead.The content is the following: 1)through the traditional installation of disc cutters traditionally designed as well as newly designed and the installation of them in accordance with the installation theory put forth,which are tested with data collected, an in-depth study has been conducted regarding the vibration mechanism of various cutter saddles with different installation on the cutterhead,their mutual response mechanism and development of dynamic load spectrum; 2)a finite element analysis pertinent to cutterhead has been carried out with digital cutterhead and load simulation developed, and research has been made on the propagation mechanism and coupling of lateral vibration wave,longitudinal vibration and circuferential vibration on the cutterhead; 3) based on the research mentioned above, vibration equations related to structure unit axes and part component middle section are presented; 4）Tests both in the laboratory and field have been conducted on the digital cutterhead produced, followed by the analysis and study of the vibration coordination mechanism of each structure unit and part component. This research provides an important foundation upon which the design theory of large-scale boring equipments will rest, and poses a crucial technological issue crying for solution not only in the scientific research but also in the economic and social development of China.

振动是影响金属结构寿命、可靠性和寄生功率产生、积聚、甚至导致焊缝或结构失效的主要因素。项目以全断面岩石掘进机刀盘为研究对象，研究内容是：1)通过传统盘形滚刀和项目组提出的设计理论设计的新型盘形滚刀的传统安装、项目组建立的安装理论的安装，通过试验室试验、数据采集，深入研究刀盘上不同安装方式的不同盘形滚刀座振动机理、刀座振动间的相互响应机理并建立刀座动态载荷谱；2)对刀盘进行有限元分析，开发数字刀盘并进行模拟加载，研究横向振动波、纵向振动波和周向振动波在刀盘内的传播机理和耦合作用机理；3)以上述研究为基础，立出结构单元轴线、零件单元中面的振动方程；4）将上述数字刀盘物理化，进行实验室试验和实际工程应用检验，进而分析、研究刀盘各结构单元、零件单元振动协调机理。研究成果可为大型掘进设备结构件研制理论提供基础依据，研究内容既是本领域科学研究发展、也是我国经济和社会发展中迫切需要解决的关键科技问题。

全断面岩石掘进机（简称：TBM）用于我国岩石质地层隧道（洞）掘进已非常普遍，但刀盘开裂、刀盘大轴承损坏、分块刀盘联接螺栓断裂及盘形滚刀非正常磨损失效等事故的发生，已严重影响甚至威胁到TBM施工。基于此，我们以研究TBM刀盘振动机理为切入点，建立了符合TBM刀盘实际结构的双钢板刀盘模型，并进一步建立了传统盘形滚刀和偏楔形盘形滚刀与刀盘组成的系统的振动模型。通过刀盘实际作业过程，研究了刀盘前后板厚度及两板间距分别变化时的刀盘静态、模态、谐响应及瞬态特性，通过这样研究发现增强TBM刀盘作业刚度可有效降低其作业过程中的振幅甚或改变其固有振动频率。以此研究为基础，我们提出了：a) 增加TBM刀盘刚度的方法——“改变刀盘与其回转支撑间联接半径的TBM”、“曲面刀盘”和“变厚度刀盘”等概念；b）有效规避TBM施工过程中刀盘固有频率接近或等于外界激励频率的方法——“改变刀盘厚度和支撑半径”；c）减缓盘形滚刀磨损后刀盘振动的方法—— “盘形滚刀刃宽和刃角确定方法”、“TBM刀盘上盘形滚刀等寿命布置方法”、“盘形滚刀磨损量预测方法”等。上述研究成果中的变厚度刀盘应用于TBM刀盘设计，在相同地质地层条件下，刀盘振幅可减小50%左右；若采用曲面刀盘，TBM施工中，刀盘振幅不仅还可进一步减小，并能使TBM刀盘上盘形滚刀的破岩力趋于均匀，从而提高盘形滚刀作业寿命和TBM利用率，缩短TBM施工工期。全断面岩石掘进机的发展已经过了第一代（一维设计理论，产生于上世纪50年代）和第二代（二维设计理论，形成于上世纪80年代），这两代TBM设计理论的提出和建立都是国外科研和工程技术人员努力的结晶。TBM在我国的应用和发展将为第三代TBM设计理论（三维设计理论——本项目组第一项国家自然基金（51075147）和此项国家自然基金（51475163）为此理论的产生和形成提供了坚实基础）的产生和应用提供广阔前景。