Research on design of small diameter TBM cutterhead in gas control roadway of Well 1 Bailongshan Coal Mine
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摘要:
白龙山煤矿一井为煤与瓦斯双突矿井，采用全断面岩石隧道掘进机（Tunnel Boring Machine, TBM）施工能更好地满足煤矿安全、高效和环保的建设需要，刀盘是决定TBM掘进效率和施工安全的关键部件，其设计是否合理对保障TBM施工效率与煤矿高效生产至关重要。通过分析煤矿瓦斯治理巷道与非煤矿领域隧道工程要求和地质特点差异，总结了煤矿瓦斯治理巷TBM刀盘设计需求，阐述了瓦斯治理巷TBM刀盘的设计流程。针对白龙山煤矿一井瓦斯治理巷开展小直径TBM刀盘设计，从刀盘盘体结构、刀具布置、出渣结构等3个主要方面确定刀盘初始方案，结合倾覆力矩、不平衡力、强度及刚度校核形成刀盘最终设计方案。白龙山煤矿一井瓦斯治理巷TBM刀盘选取平面型二分块结构，采用单螺旋线刀具布置形式，滚刀刀间距设计根据离散元仿真分析确定，铲斗均布在刀盘外周，铲斗尺寸根据出渣量确定。刀盘最大倾覆力矩为946.53 kN·m，由刀具产生的倾覆力矩为523.28 kN·m，占比为55.3%，刀具产生的水平与竖直不平衡力最大值为78.12 kN，仅为刀盘重力产生的竖直不平衡力的17.2%，刀盘最大应力为99 MPa，最大变形为0.4 mm，相当于刀盘整体厚度应变量为0.027%，满足设计要求。面向白龙山煤矿一井瓦斯治理巷提出的刀盘设计流程能够为同类工程TBM刀盘设计提供借鉴。
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关键词:
- 瓦斯治理巷 /
- 岩石隧道掘进机(TBM) /
- 刀盘设计 /
- 滚刀布置 /
- 性能校核
Abstract:Well 1 of Bailongshan Coal Mine is a coal and gas blow-out mine, the use of full-face tunnel boring machine (TBM) can better meet the needs of safe, efficient and environmentally friendly construction of coal mines. The cutterhead is a key component to determine the efficiency of TBM construction, and its reasonable design is essential to ensure the safety of coal mine production. Based on the analysis of the differences in engineering demands and geological characteristics between coal mine gas control roadway and non-coal mine tunnel, the design requirements of TBM cutterhead in coal mine gas control roadway are summarized, and the design process of TBM cutter head in gas control roadway is illustrated. The small diameter TBM cutterhead is designed for the gas control roadway in Well 1 of Bailongshan Coal Mine, and the initial scheme of the cutterhead is determined from three main aspects: the body structure, the layout of the cutters, and muck removal structure, then, the scheme of cutterhead is finally formed in combination with the verification of overturning moment, unbalanced force, strength and stiffness. The TBM cutterhead of gas control roadway in Well 1 Bailongshan Coal Mine adopts a planar two-part structure, the cutters are arranged in the form of single helix cutter layout, and the cutter spacing design is determined according to the discrete element simulation analysis. The scraper bucket is uniform distributed around the cutterhead, and its size is determined according to the volume of muck removal. The analysis of mechanical properties shows that the maximum overturning torque of the cutterhead is 946.53 kNm, and the overturning torque generated by the cutters is 523.28 kNm, accounting for 55.3%. The maximum horizontal and vertical unbalanced force generated by the cutters is 78.12 kN, which is only accounts for 17.2% of the vertical unbalanced force generated by the cutterhead gravity. The maximum stress of the cutterhead is 99 MPa and the maximum deformation is 0.4 mm, which is equivalent to that the overall thickness strain of the cutterhead is about 0.27‰, its performance meeting the design requirements. The cutterhead design process for gas control roadway in Well 1 of Bailongshan Coal Mine can provide reference for TBM cutterhead design of similar projects.
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图 1 煤巷瓦斯治理巷小直径TBM刀盘设计流程
Figure 1. Design process of small diameter TBM cutterhead in coal gas control roadway
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图 5 贯入度6 mm时不同刀间距破岩效果
Figure 5. Rock breaking effect of different cutter spacings under 6 mm penetration
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图 6 贯入度10 mm时不同刀间距破岩效果
Figure 6. Rock breaking effect of different cutter spacings under 10 mm penetration
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图 12 标准负载工况刀盘应力及变形云图
Figure 12. Nephogram of cutterhead stress and deformation under standard load condition
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图 13 脱困工况刀盘应力及变形云图
Figure 13. Nephogram of cutterhead stress and deformation under extrication condition
表 1 离散元细观参数
Table 1 Micro parameters of DEM
颗粒密度/(kg·m−3) 有效模量/GPa 刚度比 摩擦因数 平行黏结有效模量/GPa 平行黏结刚度比 抗拉强度/GPa 黏结强度/GPa 内摩擦角/(°) 2660 5.0 2.5 0.577 5.0 2.5 27 20 23 
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表 2 不同网格精度下刀盘最大应力
Table 2 Maximum stress of cutterhead under different grid accuracy
网格模型 网格数量/万 最大应力/MPa 模型1 20 92.31 模型2 35 98.73 模型3 70 97.84
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