Prediction of TBM cutter wear in heterogeneous ground under high ambient pressure

To prevent tunnel face collapse in heterogeneous ground, the applied face pressure in the excavation chamber can be increased to stabilise the tunnel face, which may hinder cutter rotation during tunnel boring machine (TBM) tunnelling. This study proposes a TBM cutter wear prediction model that considers the impact of the variation in the cutter normal force on the cutterhead owing to the high applied face pressure and low penetration rate. First, the cutter motion mode in heterogeneous ground is investigated. The cutter is found to slide when cutting soft rock based on an analysis of the field data. The evolution process of the cutter wear morphology under heterogeneous ground conditions is summarised. A method for calculating the cutter normal force when the cutter slides on the tunnel face is proposed by referring to the cutting mechanism of the drag bits. The cutter hardness is measured on-site using a portable hardness tester. A semi-empirical model considering the variation in the cutter normal force on the cutterhead is proposed to predict the cutter wear in heterogeneous ground. Wear prediction is compared with other predictive models and field data for validation, and the discrepancies between the different models are discussed. The results show that the proposed model is effective for predicting TBM cutter wear under complex geological conditions.