Based on the practical requirements of TBM cutterhead manufacturers, a fundamental design workflow for cutterheads has been established. By integrating geological tunneling conditions, cutterhead structural parameters, and operational tunneling parameters, computational models were developed for key design elements-such as cutter layout, opening configuration, and cutterhead body design-leading to the proposal of a corresponding design methodology for enhancing TBM cutterhead adaptability to specific geological environments. This design workflow encompasses the selection of the cutterhead body type, cutter arrangement, muck chute design, and support structure design.
In practical engineering applications, the selection of cutters and the determination of primary operational parameters (including cutter spacing, penetration depth, thrust, and torque) must be guided by the prevailing geological conditions. Tools such as ANSYS are utilized to conduct simulations for mechanical performance analysis (specifically assessing maximum deformation and stress levels), while Discrete Element Method (DEM) simulations are employed to analyze muck removal efficiency. Furthermore, a strain reconstruction method-based on BP neural networks and Finite Element Analysis (FEA)-can be applied to monitor strain at critical locations on the TBM cutterhead, thereby addressing the challenges associated with strain monitoring under severe operating conditions.
Cutterhead design must effectively address complex geological environments, including high-hardness rock strata, water-rich sandy layers, and composite ground formations. Notably, the design of cutterheads for full-face hard rock TBMs used in coal mining differs from that of conventional hard rock TBMs, as they must adhere to specific dimensional and weight constraints imposed by the requirements for underground transportation and assembly. Design innovations are frequently tailored to meet specific project demands; examples include the targeted design features adopted for the "Caucasus" hard rock TBM-such as synchronous tunneling and segment erection technology, active articulation systems, and bi-directional rotating cutterheads.
