Design Optimization For Diaphragm Trench Cutting Wheel

The diaphragm construction process with the cutting wheel set is the most advanced one of diaphragm construction processes. The cutting wheel set, which integrates mechanics, electrics and hydraulics, represents the highest level of the development of diaphragm construction technology. Research on this technology has not been done yet in China. With increase in large construction projects in China, it is urgent to make some breakthrough in research on this technology. Very little technical information on cutting wheels is available in publicized literature due to technical confidentiality. In this paper, theoretical calculations are made with finite element static and dynamic simulations, and lab and field experiments for the key element of the cutting wheel set- the cutting wheel in terms of kinematics and dynamics, and structure, parameters, material, and machining process of its spare parts under the research program"Development of ZC30 Trench Cutting Wheel Set"jointly undertaken by the Institute of Exploration Techniques and Zoomlion.This paper is comprised of six parts: Introduction; Kinematics & Dynamics of Cutting Wheel and Rock Fragmentation Manner, Finite Analysis of Rock Fragmentation with Cutting Wheel and Lab Experiment, Optimization of Parameters for Standard Cutting Elements, Overall Design of Cutting Wheel, Conclusion and Prospect. First, with analysis of the movement trajectory of the cutting wheel, the approaching and leaving angles of the cutting wheel are calculated, and the relation of the number of teeth on the cutting wheel, rpm and feed speed of the cutting wheel to the cutting area of the cutting wheel and the remaining side wall profile is deduced. The mechanical model is created for rock fragmentation with the cutting wheel through study of the cutting wheel kinetics based on dynamics, and the formula is inferred for calculation of the main force which drives the cutting wheel to cut rock. Analysis is also made of the active and the passive factors which affect cutting loads. With the ANSYS finite analysis software, the structural parameters and the drive power of the cutting wheel are tentatively determined in qualitative and quantitative ways through the dynamic imitation of rock fragmentation with the cutting wheel by changing the cutting parameters and the structural parameters of the cutting wheel. On the basis of theoretical analysis and the COSMOSXpress finite analysis, design optimization is made for the cutting elements, structural parameters and the machining process of the cutting wheel; a compound process combining welding and heat treatment of the cutting teeth and the shanks is developed; and a new sectional structure -hard, soft and hard, is designed for assembling the cutting elements and the mounts; which extends the service life of the cutting wheel. The overall design is made for the 1m cutting wheel taking into account of the cutting element arrangement rule, spoil suction and discharge requirements, and rock wall cleaning with the flapping teeth. In the end, the conclusions and novelties are summarized of the research on the cutting wheel with the development trend predicted.R & D of the cutting wheels has not been conducted in China until recently and lots of work remains to be done in introduction, assimilation, research and improvement of the foreign advanced technology. The research on the cutting wheel in this paper is of great significance to make the cutting wheels domestically and promote the diaphragm wall construction process with the cutting wheel in China, and also lays a foundation for development of the cutting wheel set of Chinese intellectual property.