阅读说明：本技术 一种新型tbm滚刀刀圈 (Novel TBM hobbing cutter ring ) 是由 张蒙祺 莫继良 周仲荣 勾斌 段文军 章龙管 牟松 苏叶茂 于 2021-07-30 设计创作，主要内容包括：本发明公开了一种新型TBM滚刀刀圈,属于TBM滚刀领域,针对现有技术中常用盘形平头滚刀岩石的接触面积大,岩石过度破碎,破岩比能高的问题,包括刀圈基体,所述刀圈基体中心开设有刀毂安装孔,外缘加工有刃口；所述刃口两侧加工有主刃；所述刃口绕刀圈轴线均匀开设有泄压槽；所述泄压槽之间形成刃齿；所述刃齿两边形成副刃,其目的在于,减小滚刀刀圈与岩石的接触面积,降低刀盘的推力,改变密实核形状和应力分布,减少岩石的过渡破碎体积,降低滚刀破岩比能,提高破岩效率。(The invention discloses a novel TBM hob ring, which belongs to the field of TBM hobs and aims at solving the problems that in the prior art, the contact area of common disc-shaped flat-head hobs is large, rocks are excessively crushed, and the rock breaking ratio is high; main blades are processed on two sides of the cutting edge; the cutting edge is uniformly provided with pressure relief grooves around the axis of the cutter ring; blade teeth are formed between the pressure relief grooves; the secondary blades are formed on two sides of the blade teeth, and the secondary blades are used for reducing the contact area of a hob ring and rock, reducing the thrust of a cutter head, changing the shape and stress distribution of a compact core, reducing the transitional crushing volume of the rock, reducing the rock breaking specific energy of the hob and improving the rock breaking efficiency.)

1. The novel TBM hob is characterized by comprising a hob ring base body (1), wherein a hob hub mounting hole (2) is formed in the center of the hob ring base body (1), and a cutting edge (7) is machined in the outer edge of the hob ring base body; the main blades (3) are processed on two sides of the cutting edge (7); the cutting edge (7) is uniformly provided with pressure relief grooves (4) around the axis of the cutter ring; blade teeth (5) are formed between the pressure relief grooves (4); and auxiliary blades (6) are formed on two sides of the blade teeth (5).

2. A novel TBM hob according to claim 1, characterized in that the cross section of the pressure relief groove (4) comprises a rectangle, a trapezoid or an arc.

3. The novel TBM hob according to claim 1, wherein the pressure relief groove (4) is a spiral groove formed in a spiral line coaxial with the hob hub mounting hole (2), and the spiral groove is uniformly distributed on the outer peripheral surface of the hob base body (1), so that the contact area between the hob and the rock surface is smaller.

4. A novel TBM hob according to claim 3, wherein the pressure relief groove (4) has a groove number Z of 10-18, a helix angle β of 30-80 °, a width B < T x (cos ((π/2) - β)), wherein T is the hob edge width, and an adjacent groove included angle of 20-36 °.

5. The novel TBM hob according to claim 1, wherein the cutter ring base body (1) is made of 40CrNiMo or 4Cr5MoSiV 1.

6. A new TBM hob according to claim 1, characterized in, that each root edge of the blade teeth (5) is rounded.

7. A novel TBM hob according to claim 6, wherein the contact surface of the blade teeth (5) and the rock is a diamond shape with uniform distribution, the number of teeth Z ' is 10-18, the acute angle α ' is 10-60 °, and the included angle between adjacent grooves with the width B ' of > (π D/Z ') × (sin α ') -T × (cos ((π/2) - β)) is 20-36 ° to ensure that the hob and the rock are always in continuous contact.

8. A novel TBM hob according to claim 1 and claim 4, characterized in that the cutter ring base body (1) and the pressure relief groove (4) are formed by die forging.

9. The novel TBM hob according to claim 1, characterized in that the cutter ring base body (1) and the edge teeth (5) are strengthened by heat treatment and WC coating.

Technical Field

The invention belongs to the technical field of TBM cutters, and particularly relates to a novel TBM hob ring.

Background

The full-face Tunnel Boring Machine (TBM) is a special engineering machine for tunneling, has safe excavation and lining, and has high tunneling speed; the whole processes of propelling, unearthing, splicing lining and the like can realize automatic operation, and the construction labor intensity is low; ground traffic and facilities are not influenced, and facilities such as underground pipelines and the like are not influenced; the tunnel has the advantages of no influence on shipping when passing through a river channel, no influence of weather conditions such as seasons, wind, rain and the like in construction, no noise and disturbance in construction and the like, and is widely used for tunnel engineering of railways, highways, municipal administration, hydropower and the like. According to statistics, the cost brought by the cutter directly or indirectly accounts for about 1/3 of the total construction cost of the shield tunnel, so that the exploration of the cutter is quite important for the shield construction. The hob is a main cutter for cutting broken rocks on a TBM (Tunnel Boring Machine), is usually arranged on a cutter head in a spiral line, revolves along with the cutter head in the process of TBM Boring, and simultaneously rotates around the axis of the hob under the friction action of rocks and the like. The hob presses the rock face under the combined action of the cutter thrust and the torque, and when the contact pressure exceeds the strength of the rock, the rock is broken into fragments. The conventional hob disc-shaped constant-section flat-end hob (CCS) has large contact area with rocks, so that the thrust of a hob disc is large, the rocks are excessively crushed, the rock breaking specific energy is high, the propulsion efficiency of the hob disc is low, and the construction cost is high.

Through the early tracking shield tunneling construction condition and the combination of a large amount of literature research and analysis, the research on the design of the novel TBM hob ring in part of colleges and universities and enterprises is developed, and considerable achievements are obtained, but some limitations still exist on the research work of the TBM hob ring:

1. when the shield tunneling machine tunnels, a hob on a TBM cutterhead revolves along with the rotation of the cutterhead, and simultaneously rotates around a hob shaft, and the linear speed of the rotation is higher under the condition of not considering blocking rotation, namely pure sliding (such as hob string grinding), especially the linear speed of an edge hob of the TBM cutterhead with a large diameter can reach more than 1.5 m/s; in the process of TBM construction, various complex composite strata (such as strata with soft upper part and hard lower part, cobblestone or moderately weathered sandstone) are frequently encountered, namely, the hobbing cutter ring is subjected to high-frequency and high-amplitude impact load in the construction process, so that great challenge is brought to the toughness of the hobbing cutter ring, and abnormal wear conditions such as tipping and fracture of the TBM hobbing cutter ring can be caused. To reduce these phenomena, some researchers have proposed new designs for hob rings. For example, the shin-region diamond drilling tool company Limited invented "a combined shield hobbing cutter ring" (patent No. ZL201710826091.8), the hobbing cutter ring is designed by being divided into an inner ring and an outer ring, the inner ring is connected with the body of the hobbing cutter in an interference fit manner, the outer ring is designed into a plurality of hard alloy blocks with arc-shaped steel structures, the hard alloy blocks are fixed on the inner ring through bolts, the inner ring can absorb the impact load of the cutting edge of the hobbing cutter ring, and the probability of the cutting edge of the hobbing cutter ring breaking due to the impact load is reduced. Gaps exist among the hard alloy blocks with the outer ring arc-shaped structures, and the hard alloy blocks are used for performing fine movement, dissipating energy generated by impact load and reducing the probability of breakage of the hob ring. However, the inner ring and the outer ring of the hob ring are connected through the bolts, and under long-term random impact load, the inner ring and the outer ring may have fretting wear, bolt looseness, bolt fatigue fracture and other conditions, so that the danger of falling of the hard alloy block with the arc-shaped steel structure is caused, and further, irreversible damage is caused to other parts such as the hob, the cutter head and the like.

2. Under the actual tunneling working condition, the TBM hob is mainly used for full-face hard rock construction generally, the load borne by the hob during construction is large, generally more than 10T, and some of the load can even reach 25T, so that the TBM hob ring is crushed due to insufficient strength in construction to cause abnormal fracture. In response to this phenomenon, some researchers have innovated the design concept of the cutter ring. For example, Anhui Shunhong mechanical equipment science and technology Limited company develops a 'hob ring suitable for hard rock tunneling' (patent number: ZL201920400407.1), wherein a first sharp edge and a second sharp edge are machined on the periphery of the outer wall of a conventional flat-end hob ring around the axis of the hob ring, the widths of the first sharp edge and the second sharp edge are 1mm, the cutting edge of the whole sharp edge is thin, and the resistance of the hob when the hob penetrates into a rock face can be greatly reduced. However, the edge width and the edge height of the sharp edge of the hob ring are small, and the sharp edge is easy to wear and lose the original design effect for the conventional flat-end hob ring.

Disclosure of Invention

Aiming at the problems of large contact area of common disc-shaped flat-head hob rocks, excessive rock crushing and high rock breaking specific energy in the prior art, the invention provides a novel TBM hob ring, which aims to solve the problems that: under the form that does not change overall structure, evenly set up the helicla flute on hobbing cutter sword circle blade, change the area of contact of sword circle and rock, change the distribution of the inside closely knit nuclear of rock and stress field under the hobbing cutter effect. Compared with the common cutter ring without the pressure relief groove, the cutter ring provided with the pressure relief groove has smaller contact area with the rock surface, lower normal load, less excessive rock breakage and lower rock breaking specific energy. When a rock is broken by the hob assembled by the cutter ring with the pressure relief groove, the diamond-shaped cutting edge tooth can be more easily invaded into the rock, cracks can be more easily formed and expanded under the action of the wedge-shaped structure, and when the cracks formed by the operation of two adjacent hobs are crossed, formed rock fragments fall off, so that the rock breaking efficiency can be improved. And when the hob cutter is used for cutting rocks, the rhombic blade teeth gradually cut into the rocks, so that the impact load borne by the hob cutter when the hob cutter is used for cutting the rocks is small. The design structure is simple, the machining is easy, and the influence of the manufacturing cost is small.

The technical scheme adopted by the invention is as follows:

a novel TBM hob comprises a hob ring base body, wherein a hob hub mounting hole is formed in the center of the hob ring base body, and a cutting edge is machined in the outer edge of the hob ring base body; main blades are processed on two sides of the cutting edge; the cutting edge is uniformly provided with pressure relief grooves around the axis of the cutter ring; blade teeth are formed between the pressure relief grooves; the two sides of the blade tooth form secondary blades.

Preferably, the cross section of the pressure relief groove comprises a rectangle, a trapezoid or an arc.

Preferably, the pressure relief groove is a spiral groove formed in a spiral line form coaxial with the cutter hub mounting hole, and the spiral groove is uniformly distributed on the outer peripheral surface of the cutter ring base body, so that the contact area between the cutter ring and the rock surface is smaller.

More preferably, the pressure relief grooves have a groove number Z of 10 to 18, a helix angle beta of 30 to 80 degrees, and a width B < T x (cos ((π/2) - β)), wherein T is a hob edge width, and an adjacent groove angle of 20 to 36 degrees.

Preferably, the cutter ring base body is made of 40CrNiMo or 4Cr5MoSiV 1.

Preferably, each root edge of the blade tooth is subjected to a fillet treatment.

Preferably, the contact surface of the blade teeth and the rock is in a diamond shape which is uniformly distributed, the number of teeth Z ' is 10-18, the acute angle alpha ' is 10-60 degrees, and the included angle between adjacent grooves with the width B ' of > (pi D/Z ') × (sin alpha ') -T x (cos ((pi/2) -beta)) is 20-36 degrees so as to ensure that the hob and the rock are always in continuous contact.

Preferably, the cutter ring base body and the pressure relief groove are formed by die forging.

Preferably, the cutter ring base body and the cutter teeth are strengthened through heat treatment and WC coating.

In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:

1. under the form that does not change overall structure, reduce the area of contact of cutter ring and rock, reduce the power of blade disc, reduce the excessive breakage of rock, reduce broken rock specific energy for the crushing speed of rock, reduce cost reduces the construction period.

2. The pressure relief groove is arranged to change the contact area of the cutter ring and the rock, change the distribution of the inside compact core and the stress field of the rock under the action of the hob, reduce the thrust of the cutter head, reduce the rock breaking specific energy, accelerate the breaking speed of the rock, reduce the construction cost and reduce the construction period. The design structure is simple, the processing is easy, and the influence of the manufacturing cost is small.

3. Stress distribution is changed in the arrangement of the pressure relief groove, so that the original powdery rock debris is presented as a large sample at the pressure relief groove, excessive crushing of rock slag is reduced, and specific energy is reduced.

4. The setting of sword tooth has reduced the area of contact of hobbing cutter ring with the rock, increases the contact pressure of hobbing cutter ring to the rock for the crushing speed of rock.

5. The rhombus arrangement of the edge teeth can enable the edge teeth to gradually invade rocks when the rocks are broken, so that the contact area is gradually changed, the impact caused by the change of the contact area is reduced, meanwhile, the rhombus edge teeth have a wedge effect, tensile cracks are easier to form, and the rock breaking efficiency is improved.

6. Due to the design of the diamond-shaped edge teeth, the secondary edge can be newly formed, so that the total edge length of the hob ring is increased, the distribution of tensile stress (which can promote the breaking of rocks) is wider, tensile cracks are easier to form, the germination and the expansion of cracks are promoted, and the rock breaking efficiency is improved.

Drawings

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic of the present invention.

Fig. 2 is a schematic view of a conventional flat head disc cutter.

Fig. 3 is a front view of the present invention.

Fig. 4 is a side, semi-sectional view of the present invention.

FIG. 5 is a developed plan view of the blade of the present invention.

Fig. 6 shows a typical shape 1 of the cross section of the pressure relief groove according to the invention.

Fig. 7 is a typical shape 2 of the cross section of the pressure relief groove of the present invention.

Fig. 8 is a typical shape 3 of the cross section of the pressure relief groove of the present invention.

Fig. 9 is a rock fragment distribution diagram of the single-blade simulated rock breaking of the present invention.

FIG. 10 is a rock fragment distribution diagram of a conventional cutter ring single-blade simulation rock breaking.

Fig. 11 is a rock fragment distribution diagram of a double-blade simulated rock breaking of the present invention.

Fig. 12 is a rock fragment distribution diagram of a conventional cutter ring double-cutter simulated rock breaking.

Fig. 13 is a comparison graph of the simulated rock breaking average normal load.

Fig. 14 is a comparison graph of the simulated rock breaking average rolling force.

Fig. 15 is a comparison graph of simulated rock breaking specific energy.

Fig. 16 is a comparison graph of the average rolling force of the simulated rock breaking.

Fig. 17 is a comparison graph of the average rolling force of the simulated rock breaking.

Fig. 18 is a comparison graph of the average rolling force of the simulated rock breaking.

The following are marked in the figure:

1-cutter ring matrix, 2-cutter hub mounting holes, 3-main blades, 4-pressure relief grooves, 5-blade teeth, 6-auxiliary blades and 7-cutting edges.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all the embodiments. The components of embodiments of the present application, generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present application, presented in the accompanying drawings, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present application without making any creative effort, shall fall within the protection scope of the present application.

In the description of the embodiments of the present application, it should be noted that the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings or orientations or positional relationships that the products of the present invention are usually placed in when used, and are only used for convenience of description and simplicity of description, but do not indicate or imply that the devices or elements that are referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present application. Furthermore, the terms "first," "second," "third," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance.

The present invention will be described in detail with reference to fig. 1 to 18.

Referring to fig. 1, the present invention provides a novel TBM hob ring, which includes: the cutter ring comprises a cutter ring base body 1, a cutter hub mounting hole 2, a main blade 3, a pressure relief groove 4, blade teeth 5 and an auxiliary blade 6. The cutter ring base body 1 is disc-shaped, the cutting edge 7 is an arc surface, a cylindrical surface or other surfaces, and the novel TBM hob cutter ring structure reduces rock breaking load by adopting a mode of arranging a pressure relief groove 4 on the cutting edge 7 of the cutter ring base body 1, so that rock breaking efficiency is improved; the pressure relief groove 4 formed in the cutting edge 7 of the cutter ring base body 1 is formed in a spiral line form coaxial with the cutter hub mounting hole 2, and the cross section of the pressure relief groove 4 can be in any shape meeting the processing requirements and the technical requirements.

Referring to fig. 2 to 8, the cutter ring base 1 has a disc-shaped structure as a whole, and the inner side of the cutter ring base 1 is a cylindrical annular inner wall and is subjected to chamfering treatment to facilitate installation of the hob hub; the middle part of the outer side of the cutter ring base body 1 protrudes outwards, the outermost surface of the protruding part is a cylindrical surface which is coaxial with the cutter hub mounting hole 2, the cylindrical surface is an incomplete surface, the outer circumferential surface of the cutter ring base body 1 is provided with a spiral pressure relief groove 4 structure inwards to improve rock breaking efficiency, the cutter ring base body 1 of the embodiment is provided with the pressure relief groove inwards, the cross section of the pressure relief groove can be rectangular, trapezoidal, arc-shaped or other shapes which meet processing requirements and technical requirements, the pressure relief groove is uniformly distributed on the outer circumferential surface of the cutter ring base body 1, the number of the grooves (Z) is 10-18, the spiral angle (beta) is 30-80 degrees, the width (B) < T x (cos ((pi/2) -beta)) (T is the width of a hob edge), the included angle of adjacent grooves is 20-36 degrees, and the pressure relief groove is formed in a spiral line mode which is coaxial with the cutter hub mounting hole 2.

Referring to fig. 9-18, when a conventional hob ring breaks rock, hob indentations are in a belt shape and are continuously distributed, the contact area is large, the normal load and the rolling force of the hob are large, rock slices under the hob indentations are obviously broken in a transitional manner, and the rock breaking specific energy is high. According to the embodiment of the invention, the blade shape of the hob ring is reasonably designed, so that the hob impression is uniformly distributed in a rhombus shape when the hob ring breaks rock, the included angle of the acute angle (alpha ') of the hob ring is 10-60 degrees, the width (B') > (pi D/Z ') × (sin alpha') -T x (cos ((pi/2) -beta)) of the adjacent grooves is 20-36 degrees, and the hob ring is always kept in contact with the rock surface; the pressure relief groove 4 formed in the hob ring base body 1 can reduce the contact area between the hob ring and rock, the normal load of the hob and the rolling force. The arrangement of the pressure relief groove 4 changes the stress distribution, so that the originally powdery rock debris is presented as a larger sample at the pressure relief groove 4, the transitional crushing of rock slag is reduced, and the specific energy is reduced; the reduction in the total number of cracks also confirms from the side that the provision of the pressure relief groove 4 can reduce excessive fragmentation of the rock slag. According to the invention, the proportion of the tensile crack in the total crack is high during rock breaking, and the design of the diamond-shaped edge teeth 5 can newly form the auxiliary edge 6, so that the total edge length of the hob ring is increased, the distribution of tensile stress (the tensile stress can promote the rock breaking) is wider, the tensile crack is easier to form, the germination and the expansion of the crack are promoted, and the rock breaking efficiency is improved.

The processing technology of the invention is as follows: blanking common materials of the TBM hob ring according to requirements, then forming a blank of the novel TBM hob ring with the characteristics of a hub mounting hole 2, a pressure relief groove 4, a blade tooth 5 and the like through die forging, annealing the forged workpiece blank, and machining after the workpiece is cooled; then carrying out conventional TBM hob ring heat treatment on the workpiece; cleaning the heat-treated workpiece, and grinding the end face and the cutter hub mounting hole 2 again to meet the requirements on the size and the smoothness of the TBM hob ring; finally, the edge teeth 5, the cutting edge 7 and the like are subjected to carburization or coating (WC) strengthening.

In particular, the cross-sectional shape of the relief groove 4 formed in the hob ring base 1 is not limited to the above-mentioned shape, and it is within the scope of the present invention to provide the hob ring with a uniform groove, hole or other recessed geometric structure formed on the outer circumferential surface of the hob ring along the coaxial spiral line of the hob ring.

In summary, the embodiment of the invention changes the contact area and stress distribution through reasonable knife ring edge shape design and the structure of the non-flat and non-uniform surface of the knife ring, so that cracks are easier to form and expand, simultaneously reduces the load of a cutter head, reduces the volume of a compact core, reduces the specific energy of rock breaking, improves the rock breaking efficiency, and increases the tensile stress at the edge teeth 5 under the action of wedge effect by gradually invading the rock by the diamond edge teeth 5 so that the cracks are easier to form and expand; according to the invention, the contact area of the cutter ring and the rock is changed, and the stress distribution is changed, so that the formation and the expansion of cracks are facilitated, the rock breaking capacity is effectively enhanced, and the rock breaking efficiency is improved.

The above-mentioned embodiments only express the specific embodiments of the present invention, and the description thereof is specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for those skilled in the art, without departing from the technical idea of the present application, several changes and modifications can be made, which are all within the protection scope of the present application.