复合型土压平衡盾构刀盘布刀规律研究及刀盘CAD系统开发
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摘要
随着我国经济的快速发展,基础工程建设需求与日俱增,盾构法俨然已成为轨道交通、市政管线、引水灌溉、西气东输等工程建设项目的主要施工方式。刀盘作为盾构机的关键部件,其作用主要是破碎剥离岩土、实现碴土过流以及支撑开挖界面。刀盘上合理的刀具布置是保证盾构机高效稳定掘进的前提,也是保证刀盘受力平衡,提高掘进界面稳定性,延长刀盘刀具以及大轴承寿命的关键。在查阅大量国内外文献的基础上,对复合型土压平衡盾构刀盘上刀具布置规律和刀盘CAD系统的开发进行了相关研究,论文主要研究工作如下：
(1)分析了复合型土压平衡盾构刀盘典型刀具的布置规律。首先分析了滚刀的布置方式；采用UDEC对双刀顺次加载进行数值模拟,计算刀具切削比能耗,根据比能耗最小原则确定滚刀最优刀间距,并通过切削实验和工程应用验证了该数值仿真方法的可行性；结合实际刀盘分析了复合型土压平衡盾构刀盘上刮刀布置的两种常见方式。
(2)采用遗传算法对滚刀布置优化模型进行求解。根据复合型土压平衡盾构刀盘的构形特点,将刀盘按开口分为8类,由此获得滚刀布置区域；以最小化刀盘不平衡力和破岩量差异为优化目标建立滚刀布置优化模型,采用分段方式进行求解；以深圳市地铁线路某盾构施工标段用刀盘的滚刀布置设计为例,验证了该滚刀布置优化模型和遗传算法求解该模型的可行性和有效性。
(3)初步开发了复合型土压平衡盾构刀盘CAD系统。说明了目标系统要实现的基本功能,并提出了相应的设计要求；以三维软件SolidWorks作为开发平台,以Visual Basic作为开发工具,采用编程法与基于模板法相结合的方式实现参数化建模功能；最后结合深圳市地铁线路某施工标段的工程需求,应用所开发的复合型土压平衡盾构刀盘CAD系统针对具体地质条件,设计了相应的刀盘。
With the increasingly rapid economic development as well as the demand for basic project constructions, shield tunneling has become a main construction method in project, such as the rail transportation, municipal pipelines, irrigation, and natural gas and so on. The cutterhead is a critical component of shield machine and it plays a major role to break rock and support the tunneling interface. The reasonable arrangement of cutters is not only the guarantee of tunneling efficiently and stably, but also the key to balance the forces of cutters, improve tunnel face'stability, and extend the life of cutters and the main bearing. Based on substantial literature, the arrangement law of cutters and the development of cutterhead CAD system on the composite EPB shield are studied. The main researches of this paper can be summarized as follows:
(1) The arrangement law of typical cutters of cutterhead on the composite EPB shield is analyzed. Firstly, arrangement mode of disc cutters are analyzed. The numerical simulation of loading serially on two disc cutters has been carried out using UDEC. Then the specific energy consumption of disc cutters is calculated. According to the principle of minimum specific energy consumption, the optimization cut spacing of disc cutters is determined. The feasibility of the numerical simulation method is verified by the cutting experiment and engineering application. Also, two common modes to arrange cutters on the composite EPB shield cutterhead are proposed by analyzing the actual cutterhead.
(2) Genetic Algorithm is used here to solve the optimization model of the disc cutters arrangement. According to their structural characteristics, the cutterheads of the composite EPB shield are divided into eight types due to the distribution of cutterhead opening, and then the arrangement area of disc cutters is obtained. A optimization model of disc cutters arrangement is established to minimize cutterhead's unbalanced force and the difference of the rock breaking amount. And it is solved by the subsection method. Taking the disc cutters arrangement design of the cutterhead used in a subway line construction of Shenzhen for example, the result turns out that the optimization model of disc cutters and the Genetic Algorithm to solve this model are both feasible and effective.
(3) A cutterhead CAD system for the composite EPB shield is developed preliminary. The basic functions and the corresponding design requirements of the target system are described. The system services 3D software SolidWorks as a development platform and Visual Basic as a secondary development language, then the combination of programming method and template-based approach is used to realize the function of parametric modeling. Furthermore, combined with the engineering demand of a subway line construction of Shenzhen, the cutterhead is designed using the cutterhead CAD system according to the geological conditions.
(1)分析了复合型土压平衡盾构刀盘典型刀具的布置规律。首先分析了滚刀的布置方式；采用UDEC对双刀顺次加载进行数值模拟,计算刀具切削比能耗,根据比能耗最小原则确定滚刀最优刀间距,并通过切削实验和工程应用验证了该数值仿真方法的可行性；结合实际刀盘分析了复合型土压平衡盾构刀盘上刮刀布置的两种常见方式。
(2)采用遗传算法对滚刀布置优化模型进行求解。根据复合型土压平衡盾构刀盘的构形特点,将刀盘按开口分为8类,由此获得滚刀布置区域；以最小化刀盘不平衡力和破岩量差异为优化目标建立滚刀布置优化模型,采用分段方式进行求解；以深圳市地铁线路某盾构施工标段用刀盘的滚刀布置设计为例,验证了该滚刀布置优化模型和遗传算法求解该模型的可行性和有效性。
(3)初步开发了复合型土压平衡盾构刀盘CAD系统。说明了目标系统要实现的基本功能,并提出了相应的设计要求；以三维软件SolidWorks作为开发平台,以Visual Basic作为开发工具,采用编程法与基于模板法相结合的方式实现参数化建模功能；最后结合深圳市地铁线路某施工标段的工程需求,应用所开发的复合型土压平衡盾构刀盘CAD系统针对具体地质条件,设计了相应的刀盘。
With the increasingly rapid economic development as well as the demand for basic project constructions, shield tunneling has become a main construction method in project, such as the rail transportation, municipal pipelines, irrigation, and natural gas and so on. The cutterhead is a critical component of shield machine and it plays a major role to break rock and support the tunneling interface. The reasonable arrangement of cutters is not only the guarantee of tunneling efficiently and stably, but also the key to balance the forces of cutters, improve tunnel face'stability, and extend the life of cutters and the main bearing. Based on substantial literature, the arrangement law of cutters and the development of cutterhead CAD system on the composite EPB shield are studied. The main researches of this paper can be summarized as follows:
(1) The arrangement law of typical cutters of cutterhead on the composite EPB shield is analyzed. Firstly, arrangement mode of disc cutters are analyzed. The numerical simulation of loading serially on two disc cutters has been carried out using UDEC. Then the specific energy consumption of disc cutters is calculated. According to the principle of minimum specific energy consumption, the optimization cut spacing of disc cutters is determined. The feasibility of the numerical simulation method is verified by the cutting experiment and engineering application. Also, two common modes to arrange cutters on the composite EPB shield cutterhead are proposed by analyzing the actual cutterhead.
(2) Genetic Algorithm is used here to solve the optimization model of the disc cutters arrangement. According to their structural characteristics, the cutterheads of the composite EPB shield are divided into eight types due to the distribution of cutterhead opening, and then the arrangement area of disc cutters is obtained. A optimization model of disc cutters arrangement is established to minimize cutterhead's unbalanced force and the difference of the rock breaking amount. And it is solved by the subsection method. Taking the disc cutters arrangement design of the cutterhead used in a subway line construction of Shenzhen for example, the result turns out that the optimization model of disc cutters and the Genetic Algorithm to solve this model are both feasible and effective.
(3) A cutterhead CAD system for the composite EPB shield is developed preliminary. The basic functions and the corresponding design requirements of the target system are described. The system services 3D software SolidWorks as a development platform and Visual Basic as a secondary development language, then the combination of programming method and template-based approach is used to realize the function of parametric modeling. Furthermore, combined with the engineering demand of a subway line construction of Shenzhen, the cutterhead is designed using the cutterhead CAD system according to the geological conditions.
引文
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[8]H. Jia, F. Liu. Improvement of Planosol Solum. J.agric Engng Res,1998, (70):185-193
[9]宋克志,潘爱国.盾构切削刀具的工作原理分析.设计计算,2007,(2)：74-76
[10]管会生,高波.复合式土压平衡盾构刀具切削扭矩的研究.现代隧道技术,2008,45(2)：73-78
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[12]Teale, R.. The mechanical excavation of rock experiments with roller cutters. Int. J. Rock Mech. Min. Sci. & Geomech Abstr..1963:372-383
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[15]金国栋,黄士房,虞和霁等.全断面岩石隧道掘进机盘刀破岩机理分析(上).制冷空调与电力机械,1981,(3)：1-9
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