隧道掘进机刀盘再制造中的多元损伤研究与剩余寿命预测

As the main equipment of tunnel construction, Tunnel Boring Machines (TBM) has been widely used in the rapid development of transportation and the constructions of diversion project. Nowadays, many boring machines have been operating close to or even beyond their designed life, which will cause a tremendous waste of resources if they are directly scrapped. According to the problem on multi-coupled failure and residual life prediction of cutter head during the boring machines` remanufacturing process, this project aims to reveal the coupling mechanism and failure modes between the multiple injuries of cutter heads with micromechanics theory, and multi-disciplinary theory and data mining technology through which establish the failure index system and the evaluation system of cutter head defects. Based on the coupling mechanism of multiple damages, establishing the residual life prediction model of remanufactured cutter heads as well as the comprehensive evaluation of cutter head will be achieved. On this basis, research on repairing strategies for remanufactured cutter heads and optimized matching method between remanufactured cutter heads and geological environment are then constructed. The next stage is to integrate project research results and establish the performance evaluation system of remanufacturing cutter heads to ensure its quality and effectiveness of service. Finally, the design methods and theories for the whole life cycle of cutter heads will be established. The research will enrich and deepen the existing basic manufacturing theory, and provide theoretical support to the construction of the Tunnel Boring Machine (TBM) remanufacturing.

隧道掘进机作为隧道工程的主要施工设备，大量应用于我国快速发展的交通、引水工程建设中。目前很多掘进机已经接近甚至超过设计寿命，若直接报废将带来巨大的资源浪费。针对废旧掘进机刀盘再制造中的多元损伤耦合与剩余寿命预测问题，本项目拟用细观力学理论、基因理论以及数据挖掘技术，揭示刀盘多元损伤间的耦合作用机理及其失效形式，建立再制造刀盘的损伤失效指标和评价体系。基于多元损伤耦合作用机理，建立再制造刀盘剩余寿命预测模型。实现对刀盘可再制造性的综合评价。在此基础上，针对再制造刀盘开展修复策略研究和再制造刀盘与地质环境的匹配优化方法研究。集成项目研究成果，建立面向再制造刀盘的性能评价体系，确保其再服役的质量和效果。最终形成面向全生命周期的刀盘设计方法和理论。该研究丰富和深化现有的再制造基础理论，并为隧道掘进机再制造施工提供方法支撑。

随着我国基础建设的推进，隧道里程数逐年上升，隧道掘进设备的各种需求也随之增加，而其中TBM再制造具有重大价值。针对TBM再制造面临的多元损伤、寿命预测、再制造刀盘与服役环境匹配等关键问题，本项目分析总结了刀盘常见的损伤类型及失效形式，借助已有的裂纹、磨损等损伤研究，分别建立了刀盘体裂纹分析模型、滚刀磨损分析模型和刀盘面板磨损分析方法，并结合理论方法建立了刀盘多元损伤演化模型框架。在此基础上，研究了刀盘的载荷获取方法，并分析了刀盘危险点的载荷特征及其影响因素，将载荷特征作为寿命分析的重要依据，研究并建立了刀盘的寿命预测方法，分析了在不同地质、损伤耦合等条件下刀盘的寿命演变规律，并定义了基于地质软硬性、刀盘失效区域性以及寿命匹配性等方面的再制造评价指标。最后，研究了止裂方案和滚刀磨损再制造修复方法；建立了刀盘再制造评价体系，制定了刀盘再制造方案，并将项目过程中的磨损损伤研究和滚刀破岩比能研究用于完善刀盘设计理论，丰富了现有的再制造基础理论和刀盘设计理论。