为探究直线段与曲线段隧道工况下岩石隧道掘进机（TBM）刀盘滚刀的损耗规律，以北山地下实验室螺旋斜坡道TBM施工数据为基础，采用统计和力学分析方法，分析全刀盘及其不同区域滚刀的损耗特征与失效类型。研究结果表明： 1）全盘滚刀的换刀频率为297把/km，换刀主导因素为刀圈正常磨损(68.97%)、断裂 (17.23%) 及弦磨 (11.76%)，且隧道线形与高强耐磨性岩体显著提升换刀频率。2）刀圈弦磨源于高载荷致刀刃局部剥落、高温引发刀体润滑油及密封失效，进而导致刀圈转动不畅；刀圈断裂主因为相邻滚刀安装高度差叠加转弯侧向滑动。3）相较于直线段，曲线段刀圈断裂占比更高，刀圈弦磨占比更低。4）刀盘平面、锥面和弧面区域滚刀消耗量比值为1.0∶1.9∶2.6，而单位破岩量对应的滚刀消耗为锥面区域较小，平面区域次之，弧面区域较大。5）曲线段刀盘平面、锥面、弧面区域滚刀消耗量，分别为直线段对应刀盘区域的1.90、1.35、1.25倍。6）刀盘平面区域滚刀以刀圈断裂和正常磨损为主，锥面区域含3类失效，弧面区域以刀圈正常磨损为主。7）从刀盘平面至弧面区域，刀圈正常磨损占比近似线性递增，刀圈断裂占比非线性递减；相较于直线段，曲线段刀圈断裂、弦磨具有向平面区域聚集的趋势。
Herein, a case study is conducted on the spiral ramp of the Beishan underground laboratory, in which statistical and mechanical analyses are employed to investigate the consumption characteristics and failure modes of disc cutters across the entire cutterhead and within different cutterhead regions. The results indicate the following: (1) The disc cutter replacement frequency for the entire cutterhead is 297 replacements per km. The dominant causes of cutter replacement are normal wear of the cutter ring (68.97%), breakage (17.23%), and chordal wear (11.76%). In addition, the tunnel alignment and the presence of high-strength, wear-resistant rock significantly increase the cutter replacement frequency. (2) Chordal wear results from local spalling of the cutter ring under high loads, as well as from the failure of lubrication oil and seals within the cutter body caused by elevated temperatures, which leads to poor rotation of the cutter ring. Cutter ring breakage is primarily attributed to the combined effects of installation height differences between adjacent disc cutters and lateral sliding during turning. (3) Compared with linear sections, the proportion of cutter ring breakage is markedly higher in curved sections, whereas the proportion of chordal wear is lower. (4) The ratios of disc cutter consumption per unit volume of rock breakage in the plane, conical, and arc regions are 1.0∶1.9∶2.6. In terms of disc cutter consumption per unit volume of rock broken, the conical region exhibits the lowest consumption, followed by the plane region, while the arc region shows the highest consumption. (5) In curved sections, disc cutter consumption in the plane, conical, and arc regions of the cutterhead is 1.90, 1.35, and 1.25 times that in linear sections, respectively. (6) The plane region predominantly exhibits cutter ring breakage and normal wear, the conical region involves all three failure modes, and the arc region is mainly characterized by normal wear. (7) From the plane region to the arc region, the proportion of normal wear increases in an approximately linear manner, whereas the proportion of breakage decreases nonlinearly. Compared with linear sections, cutter ring breakage and chordal wear in curved sections tend to be concentrated in the plane region.
