Research On Related Technology Of Development And Simulation About Fullface Tunnel Boring Machine's Digital Mockup

Full face rock tunnel boring machine is becoming the preferred equipment to excavate the long rock tunnel in such project as high speed traffic,hydraulic engineering and public works,as it is advanced,safe and environmentally friendly.Now China is carrying out research and development of the equipment with independent intellectual property rights.But the tunnel excavation process affected by many factors is so complex that there are still more subjects to deep research.The goal of this paper is to research some key technology problems related to kinematics of disc cutters,rock breaking mechanism,dynamic cutting force prediction and virtual assembly system development based on digital mockup technology and numerical simulation technique.The dissertation contains the following aspects:(1)Kinematics equation of disc cutter and theoretical formula of rock breaking arc length about cutter's edge were deduced according to the disc cutter's rock breaking motion.A new algorithm is proposed,in which the relations between disc cutter and tunnel face was studied using space geometry theory and coordinate transformation matrix method.Matlab software was used for numerical simulation analysis.The three-dimensional numerical model of the theory crushed trajectory made by the disc cutter on the tunnel face and the arc length of the rock breakage point were obtained.Trajectory of the three-dimensional graphics and graphics section curve are plotted.Distribution of arc length of rock broken point along cutter 's edge was researched.(2)According to the characteristics of crack generation and expansion in the rock broken process,some numerical methods applied in such simulations were studied by using historical literatures.Then the basic theory and application of finite element method and smooth particle hydrodynamics method were introduced to discuss the feasibility of its application in the studies on simulation of rock broken process by disc cutter.(3)A composite model of rock breaking process under disc cutter based on smoothed particle hydrodynamics and finite element method was carried out using AUTODYN software in order to select the appropriate cutters and study the layout of cutters on cutter head for full face rock tunnel boring machine.It was researched to the rock fragmentation processes induced by V-type and constant cross-section(CCS)disc cutters used in TBM with simultaneous and sequentially loading methods.Generation and expansion of cracks were obtained in rock breaking process with different loading sequence.(4)A three-dimensional numerical model was established using AUTODYN software to research the dynamic cutting force of disc cutter.Mesh free particle and the finite element mesh are used for the composite model of rock to solve large strain and large deformation problems in rock breaking process.The numerical model was validated by using semi empirical and semi theoretical model from the Colorado School of Mines and test results with full size linear cutting machine.The force on the disc cutter in rock breaking process with different penetration and the cutter spacing,the stress distribution in rock contact zone of disc cutter with different diameter,characteristics of force with different cutter radius were systematically researched by a series of numerical simulation.(5)A digital mockup of ?5.75m full face rock tunnel boring machine was constructed based on digital prototype technology.Mainly components' loads were discussed in this dissertation,static and dynamical simulations were analyzed according to different working conditions.Virtual construction system based on the mockup was researched and developed in this dissertation.A geometric model library based on OpenFlight data format was built,and the work principle of rock tunnel boring machine can be displayed in the virtual reality environment based on software Vega.(6)A virtual assembly system about full face rock tunnel boring machine was researched and developed with Visual C++6.0 based on virtual reality technology.The system includes hardware structure,digital model and software.A special control cabinet was developed to realize the interaction in the system,which including a single chip microcomputer to communicate with computer.The virtual system can provide immersion simulation of disassemble and assembly process,by which it will be very significant to its designers,workers and operators.Therefore it has significant research value and economic benefit.