| Shield construction technology has been widely used in railway, tunnels, highway tunnels and urban underground works. Full-face tunnel boring machine (TBM) is large high-tech engineering construction equipment devoted to the excavation of the underground passage, which integrated mechanical, electrical, fluid, light and computer technology. It has many advantages, such as digging fast, quality, security, economic, environmental protection and low labor intensity. Its advantages are overwhelming comparing to the traditional method. Although there were some achievements made by foreign company, most of them are kept confidential because of commercial factors. It is necessary to do more research on key components analysis and function simulation for our full-face tunnel boring machine development independently.In order to meet the demands to improve the design and manufacture of TBM equipment with own intellectual property rights, supported by the national major scientific and technological projects-large-scale full-face TBM project funding named "Key technique research on full-face TBM numerical prototype" and the Fundamental Research Funds for the Central Universities (No. N090603006), the dissertation conducted some innovative research on several aspects as function simulation, structure analysis and virtual realization to real construction of TBM. The kinematical and dynamical simulation of segment erectoris applied. The dynamic simulation and performance analysis of TBM cutter head is discussed. The rock fragmentation mechanism is analyzed and the AUTODYN-3D numerical model is used to simulate three-dimensional dynamic failure of TBM disc cutter. A new method to predict the wear extent of cutter for TBM is developed. The dissertation includes the following aspects in detail.(1)A3D simulation system of TBM is established based on the Distributed Virtual Reality and the combination of Java/JavaScript and VRML. The function simulation and virtual assembly program for TBM are made by VRML/Java language with the movement simulation control function to realize motion simulation. It has the advantages of free installation, authenticity, interactivity, low-cost, portability, and low requiring for the clients and so on.Build up the immersive application display system of numerical prototype for TBM. By using the Onyx4system as the core, the dissertation established a virtual system for TBM which provide the reliability of the system and reduce the production costs and time-to-market.(2)The kinematical and dynamical simulation of segment erector is applied. By analyzing and simulating relevant mechanism, the speed and driving force curves are obtained for each part. Meanwhile, the maximal speed and driving force are acquired for kinematical and dynamical properties via spatial search method. Therein, this approach, which sets a reference to mechanism design and power system selection, can reduce the design cycle.(3)By using the digital prototyping technology, the performance evaluation and simulation analysis of cutterhead and disc cutter are finished. The kinematic and dynamic properties of the cutterhead are obtained. The performance evaluation, modal analysis and reliability analysis of cutter and cutterhad are finished based on finite element method. The result verifies the design of the cutter and cutterhead and meets the performance requirements in different operating conditions.(4)On the basis of building a interaction framework of numerical prototype and real machine via VR, the dissertation designed a mobile platform and manipulator robots, focusing on the analysis of its chassis movement and positioning methods; making further study of the use of servo drives and motion control of manipulator positioning method, realized the steering gear control, and initially verified the feasibility of interactive systems.(5)The cutter wear mechanism, wear forms and the wear causes are analyzed. A new model is built based on the theory of rock fracture mechanics and CSM model. The influencing factor of cutter wear is analyzed through building the mechanical model between cutter and rock and using the wear pattern of TBM. Based on Qinlin tunel project, this paper makes a quantitive study on the level of TBM cutter wear. The effectiveness of the model has been verified by the matching between prediction results and actual situation. |
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