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Efflcient machining of a complex blisk channel using a disc cutter

Chinese Journal of Aeronautics 2024年第1期37卷 414-437页

作者： Xiangyu LI Zhaoyu LI Dong HE Junxue REN Qian FENG Kai TANG Department of Mechanical and Aerospace Engineering Hong Kong University of Science and TechnologyHong Kong 999077China Key Laboratory of High Performance Manufacturing for Aero Engine(Northwestern Polytechnical University) Ministry of Industry and Information TechnologyXi’an 710072China Xi’an Sanhang Power Technology Co. LtdXi’an 710000China HKUST Shenzhen-Hong Kong Collaborative Innovation Research Institute FutianShenzhen 518057China HKUST Shenzhen Research Institute Shenzhen 518057China

For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main purpose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solution,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel twophase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the proposed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36%of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).

关键词： Blisk channel CNC machining disc cutter Roughing efficiency Tool path planning

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Study on disc cutter chipping of TBM based on field data and particle flow code simulation

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Underground Space 2023年第2期9卷 122-139页

作者： Yadong Xue Yongqiang Fan Xing Li Kai Shen Jiaxuan Wang Key Laboratory of Geotechnical and Underground Engineering of Education Ministry Tongji UniversityShanghai 200092China Department of Geotechnical Engineering College of Civil EngineeringTongji UniversityShanghai 200092China China State Construction Silkroad Construction Investment Group Co. LTDXi’an 710075China School of Civil Engineering Central South UniversityChangsha 410075China

Using tunnel boring machines to excavate high-strength intact rock masses is becoming more common.Due to the interactions between disc cutters and rocks,abnormal wear of disc cutters,especially cutter chipping,has become a common phenomenon.Existing research has mainly focused on normal wear of disc cutters without addressing abnormal wear cases.This study used the disc cutter consumption data of a tunnel project in China to investigate the abovementioned problem based on field research.According to the fail-ure patterns and fracture surface characteristics,the cutter chipping patterns were mainly categorized into four types:granule chipping,patch chipping,primary collapse,and secondary collapse.To further simulate the evolution of disc cutter chipping,based on the linear plastic bond model,a new contact model called the modified plastic bond(MPB)model was proposed to solve the metal simulation prob-lem in Particle Flow Code software.To this end,a set of uniaxial tensile and compressive tests were initially conducted to verify the applicability of the MPB model.Then,a series of three-dimensional rock-cutting simulation tests were conducted to reflect the evolu-tionary processes involved in each type of cutter chipping.The cutter chipping mechanism and morphological characteristics were clas-sified and summarized in detail.The results revealed that the cutting speed and penetration growth led to a rising trend in the probability and intensity of the cutter chipping.The presence of initial defects also induced an adverse effect on the service life of the cutter.The results indicated suitable working conditions for the cutter and suggested ways to control tunneling parameters and avoid frequent cutter chipping cases.

关键词： Tunnel boring machine disc cutter cutter chipping Particle flow code Modified plastic bond model

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Field and laboratory experimental studies on hard-rock tunnel excavation based on disc cutter coupled with high-pressure waterjet

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Frontiers of Structural and Civil Engineering 2023年第9期17卷 1370-1386页

作者： He FEI Yiqiang LU Jinliang ZHANG Xingchen LUO Yimin XIA College of Mechanical and Electrical Engineering Central South UniversityChangsha 410083China China Railway Engineering Equipment Group Co. Ltd.Zhengzhou 450016China College of Civil Engineering Tongji UniversityShanghai 200092China Yellow River Engineering Consulting Co. Ltd.Zhengzhou 450003China

The tunnel boring machine(TBM)is typically used in hard-rock tunnel excavation.Owing to the unsatisfactory adaptability of TBM to the surrounding rock,when crossing high-strength and high-wear strata,the TBM can easily cause defects,such as abnormal wear on cutters and overload damage to bearings,thus affecting the construction efficiency and cost.Therefore,high-pressure waterjet technology should be applied to assist in rock breaking for efficient TBM tunneling.In this study,the effects of water pressure,nozzle diameter,and nozzle speed on cutting are investigated via laboratory experiments of cutting hard rock using high-pressure waterjets.The penetration performance of the TBM under different water pressures is investigated via a field industrial penetration test.The results show that high-pressure waterjets are highly efficient for rock breaking and are suitable for industrial applications,as they can accommodate the advancing speed of the TBM and achieve high-efficiency rock breaking.However,during the operation of high-pressure waterjets,the ambient temperature and waterjet temperature in the tunnel increase significantly,which weakens the cooling effect of the cutterhead and decreases the construction efficiency of the TBM.Therefore,temperature control and cooling measures for high-pressure waterjets during their long-term operation must be identified.This study provides a useful reference for the design and construction of high-pressure water-jet-assisted cutterheads for breaking road headers.

关键词： tunnel boring machine hard-rock cutting free face disc cutter rock-cutting efficiency

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Design and experiment of the bionic disc cutter for kenaf harvesters

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International Journal of Agricultural and Biological Engineering 2023年第6期16卷 116-123页

作者： Kunpeng Tian Bin Zhang Aimin Ji Jicheng Huang Haolu Liu Cheng Shen Key Laboratory of Modern Agricultural Equipment and Technology(Jiangsu University) Ministry of EducationZhenjiang 212013JiangsuChina Nanjing Institute of Agricultural Mechanization Ministry of Agriculture and Rural AffairsNanjing 210014China College of Mechanical and Electrical Engineering Hohai UniversityChangzhou 213022JiangsuChina School of Mechanical Engineering Southeast UniversityNanjing 211189China

Aiming to ease the cutting of kenaf stalks via bionics,the bionic disc cutter was designed.The upper jaw of the Batocera horsfieldi was used as a bionic prototype.Further,to explore its dynamic performance,an indoor multi-stalk cutting experimental bench was used to simulate the field operation process.A three-factor and two-level interaction orthogonal experiment was carried out;cutting speed,stalk conveying speed(machine forward speed),and blade type(ordinary disc cutter and bionic disc cutter)were used as experiment factors.The cutting pass rate and cutting specific energy consumption were selected as evaluation indexes.The range,variance,and fuzzy comprehensive evaluation analysis were carried out on the experiment results.Moreover,the main order factors affecting the bionic cutter performance were determined-blade type,conveying speed,the interaction between the cutter speed and conveying speed,and cutter speed.The optimal parameter combination scheme had a cutter speed of 1000 r/min,conveying speed of 0.4 m/s,and included bionic blades.Under this condition,the best index was the 92%cutting pass rate,with a specific energy consumption of 4.38 J/stalk.The variance analysis has shown that,with 95%confidence,the blade type has a rather significant influence on the comprehensive index.Additionally,the conveying speed also significantly influenced it,while other factors and interactions had no notable effect.The experimental comparison under the same working condition shows that the bionic blade has better cutting effect.This study provides a reference for the development of cutter and the selection of kenaf harvester operational parameters.

关键词： kenaf harvester bionic disc cutter orthogonal experiment interaction

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Differentiation and analysis on rock breaking characteristics of TBM disc cutter at different rock temperatures

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Journal of Central South University 2015年第12期22卷 4807-4818页

作者：谭青张桂菊夏毅敏李建芳 College of Mechanical and Electrical Engineering Central South University Department of Mechanical and Energy Engineering Shaoyang University State Key Laboratory of High Performance Complex Manufacturing

In order to study rock breaking characteristics of tunnel boring machine(TBM) disc cutter at different rock temperatures,thermodynamic rock breaking mathematical model of TBM disc cutter was established on the basis of rock temperature change by using particle flow code theory and the influence law of interaction mechanism between disc cutter and rock was also numerically simulated.Furthermore,by using the linear cutting experiment platform,rock breaking process of TBM disc cutter at different rock temperatures was well verified by the experiments.Finally,rock breaking characteristics of TBM disc cutter were differentiated and analyzed from microscale perspective.The results indicate the follows.1) When rock temperature increases,the mechanical properties of rock such as hardness,and strength,were greatly reduced,simultaneously the microcracks rapidly grow with the cracks number increasing,which leads to rock breaking load decreasing and improves rock breaking efficiency for TBM disc cutter.2) The higher the rock temperature,the lower the rock internal stress.The stress distribution rules coincide with the Buzin Neske stress circle rules: the maximum stress value is below the cutting edge region and then gradually decreases radiant around; stress distribution is symmetrical and the total stress of rock becomes smaller.3) The higher the rock temperature is,the more the numbers of micro,tensile and shear cracks produced are by rock as well as the easier the rock intrusion,along with shear failure mode mainly showing.4) With rock temperature increasing,the resistance intrusive coefficients of rock and intrusion power decrease obviously,so the specific energy consumption that TBM disc cutter achieves leaping broken also decreases subsequently.5) The acoustic emission frequency remarkably increases along with the temperature increasing,which improves the rock breaking efficiency.

关键词： tunnel boring maching(TBM) disc cutter rock temperature rock breaking characteristic numerical simulation

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Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting

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Frontiers of Mechanical Engineering 2021年第2期16卷 285-297页

作者： Yidan WANG Renke KANG Yan QIN Qian MENG Zhigang DONG Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education Dalian University of TechnologyDalian 116024China

Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb core.The machining quality is influenced by ultrasonic cutting parameters,as well as tool orientations,which are determined by the multi-axis machining requirements and the angle control of the cutting system.However,in existing research,the effect of the disc cutter orientation on the machining quality has not been studied in depth,and practical guidance for the use of disc cutters is lacking.In this work,the inclined ultrasonic cutting process with a disc cutter was analyzed,and cutting experiments with different inclination angles were conducted.The theoretical residual height models of the honeycomb core,as a result of the lead and tilt angles,were established and verified with the results obtained by a linear laser displacement sensor.Research shows that the residual height of the honeycomb core,as a result of the tilt angle,is much larger than that as a result of the lead angle.Furthermore,the tearing of the cell wall on the machined surface was observed,and the effects of the ultrasonic vibration,lead angle,and tilt angle on the tear rate and tear length of the cell wall were studied.Experimental results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining quality.Changes in the tilt angle have less effect than changes in the lead angle on the tearing of the cell wall.The determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell wall.This study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

关键词： Nomex honeycomb core disc cutter inclined ultrasonic cutting machining quality

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Fragmentation Energy-Saving Theory of Full Face Rock Tunnel Boring Machine disc cutters

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Chinese Journal of Mechanical Engineering 2017年第4期30卷 913-919页

作者： Zhao-Huang Zhang Guo-Fang Gong Qing-Feng Gao Fei Sun School of Energy Power and Mechanical EngineeringNorth China Electric Power UniversityBeijing 102206China State Key Laboratory of Fluid Power Transmission and Control Zhejiang UniversityHangzhou 310027China School of Foreign Languages North China Electric Power UniversityBeijing 102206China

Attempts to minimize energy consumption of a tunnel boring machine disc cutter during the process of fragmentation have largely focused on optimizing disc- cutter spacing, as determined by the minimum specific energy required for fragmentation; however, indentation tests showed that rock deforms plastically beneath the cutters. Equations for thrust were developed for both the traditional, popularly employed disc cutter and anew design based on three-dimensional theory. The respective energy consumption for penetration, rolling, and side-slip fragmentations were obtained. A change in disc-cutter fragmentation angles resulted in a change in the nature of the interaction between the cutter and rock, which lowered the specific energy of fragmentation. During actual field excavations to the same penetration length, the combined energy consumption for fragmentation using the newly designed cutters was 15% lower than that when using the traditional design. This paper presents a theory for energy saving in tunnel boring machines. Investigation results showed that the disc cutters designed using this theory were more durable than traditional designs, and effectively lowered the energy consumption.

关键词： Newly design disc cutter Fragmentation Specific energy Energy consumption

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Wear Analysis of disc cutters of Full Face Rock Tunnel Boring Machine

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Chinese Journal of Mechanical Engineering 2014年第6期27卷 1294-1300页

作者： ZHANG Zhaohuang MENG Liang SUN Fei School of Energy Power and Mechanical Engineering North China Electric Power University Foreign Languages School North China Electric Power University

Wear is a major factor of disc cutters’ failure. No current theory offers a standard for the prediction of disc cutter wear yet. In the field the wear prediction method commonly used is based on the excavation length of tunnel boring machine（TBM） to predict the disc cutter wear and its wear law, considering the location number of each disc cutter on the cutterhead（radius for installation）; in theory, there is a prediction method of using arc wear coefficient. However, the preceding two methods have their own errors, with their accuracy being 40% or so and largely relying on the technicians’ experience. Therefore, radial wear coefficient, axial wear coefficient and trajectory wear coefficient are defined on the basis of the operating characteristics of TBM. With reference to the installation and characteristics of disc cutters, those coefficients are modified according to penetration, which gives rise to the presentation of comprehensive axial wear coefficient, comprehensive radial wear coefficient and comprehensive trajectory wear coefficient. Calculation and determination of wear coefficients are made with consideration of data from a segment of TBM project（excavation length 173 m）. The resulting wear coefficient values, after modification, are adopted to predict the disc cutter wear in the follow-up segment of the TBM project（excavation length of 5621 m）. The prediction results show that the disc cutter wear predicted with comprehensive radial wear coefficient and comprehensive trajectory wear coefficient are not only accurate（accuracy 16.12%） but also highly congruous, whereas there is a larger deviation in the prediction with comprehensive axial wear coefficient（accuracy 41%, which is in agreement with the prediction of disc cutters’ life in the field）. This paper puts forth a new method concerning prediction of life span and wear of TBM disc cutters as well as timing for replacing disc cutters.

关键词： full face rock tunnel boring machine disc cutter radial wear coefficient axial wear coefficient trajectory wear coefficient

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Design Theory of Full Face Rock Tunnel Boring Machine Transition cutter Edge Angle and Its Application

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Chinese Journal of Mechanical Engineering 2013年第3期26卷 541-546页

作者： ZHANG Zhaohuang MENG Liang SUN Fei School of Energy Power and Mechanical Engineering North China Electric Power University School of Foreign Languages North China Electric Power University

At present, the inner cutters of a full face rock tunnel boring machine (TBM) and transition cutter edge angles are designed on the basis of indentation test or linear grooving test. The inner and outer edge angles of disc cutters are characterized as symmetric to each other with respect to the cutter edge plane. This design has some practical defects, such as severe eccentric wear and tipping, etc. In this paper, the current design theory of disc cutter edge angle is analyzed, and the characteristics of the rock-breaking movement of disc cutters are studied. The researching results show that the rotational motion of disc cutters with the cutterhead gives rise to the difference between the interactions of inner rock and outer rock with the contact area of disc cutters, with shearing and extrusion on the inner rock and attrition on the outer rock. The wear of disc cutters at the contact area is unbalanced, among which the wear in the largest normal stress area is most apparent. Therefore, a three-dimensional model theory of rock breaking and an edge angle design theory of transition disc cutter are proposed to overcome the flaws of the currently used TBM cutter heads, such as short life span, camber wearing, tipping. And a corresponding equation is established. With reference to a specific construction case, the edge angle of the transition disc cutter has been designed based on the theory. The application of TBM in some practical project proves that the theory has obvious advantages in enhancing disc cutter life, decreasing replacement frequency, and making economic benefits. The proposed research provides a theoretical basis for the design of TBM three-dimensional disc cutters whose rock-breaking operation time can be effectively increased.

关键词： disc cutter three-dimensional mode edge angle full face rock tunnel boring machine (TBM) flat-face cutterhead

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