Page 120 - 摩擦学学报2025年第8期

1218 摩擦学学报（中英文） 第 45 卷

constructed. However, the working conditions that disc cutters face are incredibly harsh. As cutters interact with the
rock, they experience significant wear due to the nature of the material. This wear leads to a rapid deterioration of the
cutter’s edges, resulting in a high wear rate that can severely limit the cutter’s effectiveness over time. As the cutters
become blunt, their ability to break rock diminishes, leading to increased cutting forces, higher energy consumption and
ultimately reduce operational efficiency. This phenomenon of wear-induced bluntness represents a significant bottleneck
in the performance of TBMs, as it can lead to increased downtime for maintenance and replacement of cutters, as well as
higher operational costs. In response to these challenges, this study explored the innovative design of a new sprial groove
cutter that incorporated self-sharpening properties based on surface structure engineering. This study aimed to evaluate
the change in performance of this sprial groove cutter design before and after wear. Field tests were conducted to collect
real wear patterns of the helical fluted cutter and verify its self-sharpening capability. By analyzing the change in rock-
cutting performance before and after wear, it was possible to gain insight into the change in milling cutter performance
due to self-sharpening and compared it to the change in performance before and after wear of a conventional flat-top
cutter. The findings revealled a significant contrast in the wear performance between the spiral groove cutter and the
traditional flat-top cutter. Specifically, the results indicated that as the spiral groove cutter underwent wear, its rock-
cutting performance improved, which was counterintuitive compared to the performance of the flat-top cutter. For a
given depth of penetration into the rock, the worn spiral groove cutter required a reduced load and exhibited lower
specific energy consumption. This improvement could be attributed to the self-sharpening nature of the spiral groove
cutter, where the average contact area between it and the rock continued to decrease during the wear process, allowing
the spiral groove cutter to penetrate deeper into the rock formation more effectively. Conversely, the flat-top cutter
experienced an increase in the contact area as it wore down, leading to an escalation in both the cutting force and specific
energy. This increase in resistance significantly hampered the rock-cutting performance, illustrating the detrimental
effects of bluntness. The study suggested that the self-sharpening features of the spiral groove cutter could offer a viable
solution to enhance the performance and longevity of TBM disc cutters. The research on the self-sharpening capabilities
of the new spiral groove cutter provided valuable insights that could inform the design and selection processes for
cutting tools used in tunnel boring machines. By understanding the mechanisms behind wear and performance
enhancement, engineers could develop more effective cutting tools that not only improve excavation rates, but also
reduce operational costs and downtime associated with cutter replacement.
Key words: tunnel boring machine; disc cutter; wear; rock-breaking performance; self-sharpening

全断面隧道掘进机(TBM)是广泛应用于地下空间 损、黏着磨损和冲击磨损等 . 研究表明，滚刀在掘进
[9]
建设的大型机械. 相比于传统的钻爆法，TBM施工具 软岩时与脱落的岩粉反复摩擦，是造成滚刀磨损的主
有安全性强、效率高和环境友好等优点 [1–3] . 位于TBM 要原因，其磨损机理是磨粒磨损；在掘进硬岩时与岩
最前端的盘形滚刀是破岩的关键部件，其与岩石掌子 石中尖锐的矿物颗粒产生耕犁作用，导致滚刀表面出
面直接接触，通过刀盘的带动破碎岩石. 滚刀工作条 现犁沟造成磨损 [10-11] . 在滚刀磨损和刃型影响方面，研
[4]
件恶劣，不仅承受冲击重载 ，还与岩石碎屑反复摩 究表明，楔形滚刀由于刀岩接触面积小，滚刀更易贯
擦，最终导致滚刀磨损极快 [5–7] . 我国交通隧道施工面 入岩石，破岩载荷低，但是随着磨损深度加大，楔形滚
临高岩石强度、高地应力和高海拔等极端复杂地质环 刀失去尖锐结构，导致切削力迅速上升；圆顶滚刀接
[8]
境，因此需要不断提高滚刀服役的稳定性 . 然而，传 触压力集中，易产生局部磨损，半径变化较大，但质量
统滚刀不具备自锐性，随着磨损加深，滚刀逐渐钝化， 损失较小；平顶滚刀与岩石接触面较大，磨损均匀，半
[12]
进而导致破岩所需载荷上升而愈发难以贯入岩石，使 径变化较小但质量损失较大 . 上述滚刀磨损研究揭
得掘进效率显著下降. 因此，为研究滚刀磨损进程与 示了滚刀磨损机理并指出了磨损后性能退化的问题，

性能演变的关联性，本文中尝试设计应用自锐性(滚 但暂未提出有效的解决方法，同时也尚未明确滚刀磨
刀磨损后刀刃锐化，刀-岩接触面积减小) TBM刀具， 损进程与性能演变之间的关联性. 传统滚刀在磨损过
这对于保障隧道施工效率和质量具有重要意义. 程中破岩性能的降低，通常是源于刀-岩接触面积增
鉴于滚刀磨损问题的重要性，大量学者开展了多 加(刀刃钝化). 因此，可通过表面结构设计改变刀-岩
方面的研究工作，并取得了丰富的成果. 例如，在滚刀 接触状态，寻求具有自锐性的滚刀以改善滚刀性能.
磨损机理方面，滚刀磨损可分为磨粒磨损、疲劳磨 对滚刀性能的准确评估是新型刀具设计的前提