Empirical Cutting Tool Wear Prognosis 1 34 for Hydroshield TBM in Soft Ground Florian Képpl, Kurosch Thuro, and Markus Thewes Abstract ‘The wear of cutting tools is a major issue in tunneling with Hydroshield TBM in soft ground, because it is a common reason for unplanned downtime. The replacement of cutting tools requires access to the excavation chamber, which is only possible with hyperbaric works or at fixed positions with prearranged grout blocks. In order to improve predictability of the maintenance stops, an empirical prognosis model for the requited maintenance stops for changing of cutting tools and the amount of tools was developed. Based on the new Soil Abrasivity Index (SAD, the model helps to estimate distances between maintenance stops and the required amount of cutting tools to be changed, The authors validated the prognosis model based on the original reference projects. The validation lead to an adaption of the prognosis process and individual correction factors in the model itself. The article therefore describes the updated prognosis model. Keywords Hydroshield TBM + Soft ground + Excavation * Tool wear * Prognosis projects are often critical for hyperbaric works, panicularly Vel uchrers under buildings, at low overburden or very high water pressure, Képpl and Thuro (2013) developed an empirical prognosis model, to estimate the distances Lm between the maintenance ops Tand the number of eating Wools ny to be replaced, The mod enables fresited panning, in coder o avoid erica areas as described above. Validation of the prognosis model with reference to the original projets used inthe data analysis allosed to nt improvements to the prognosis process and to specify coretion factors. “The aricle summarizes the update mode ‘The replacement of cutting fools on Hydroshield TBMs is, done with hyperbaric works in the excavation chamber or at fixed positions with grout blocks, in order to maintain face stability during the interventions. ‘The position of the main- tenance stops therefore and the obtainable length of the intervals between them are determined by the wear of the cutting tools. At the same time boundary conditions in the Kopp =) Herennecht AG, Schiehenweg 2, 7963 Schwanay 134.2 Empi Almanscier, Germany ema: Locpploan@ herent. de ‘al Wear Prognosis Model 134.21 Basic Data Kee vt ce Aa 210M, ae rh ops mol ani compte ea frock tat Set’ eg aly St and Ruhr-Universitat Bochum, Universitatsstr. 180, 44780 Bochum, ‘Wendl (2010), the TBM design, e.g. the cutter head layout a tn xscehesf TM vnc eee 5. Lollino et al. (ed. Engineering Geology for Soceww and Territory ~ Volume 6, OK: 10.1007/978-3-319-00060-3_134, © Springer International Publishing Switzerland 2015 753758 For the prognosis process, homogeneous geotechnical sections are formed along the tunnel axis, using the erteria recommended by Képpl and Thuro (2013) and assigned with a whole-numbered index 2 beginning at the start of the el: Constant share of different soil types in the excavation face in % (410 %) ‘© Constant thickness of the cover above the tunnel axis in m (4S m) ‘© Constant water table above the tunnel axis in m (#5 m). 134.2.2 Estimation of the Cutting Distance S, ‘The expected value for the cutting distance s,.¢ in km of each individual too! on the cutter head within a geotechnical section is estimated using the correlation with the Soil Abrasivity Index SAl,,) which is estimated for each section EQC(,) In Eq, 134.1 EQCy) [%] is the Equivalent Quartz Con- tent, Daye Lm] the grain size where £0 % of all grains are smaller than the given value and tee) [kN/m?] the shear strength of the soil, estimated by the Mohr-Coulomb crite- rion, using the shear parameters of the soil and the vertical primary stress at the tunnel axis oy) (kN/m?]. In Bg, 134.2 hy [m] is the thickness ofthe soil layers above the tunnel axis and 7 [kN] unit weight, considering. the actual dry or saturated conditions: = % SA) (134.1) Ge (134.2) ‘The basic value of the cutting distance s.42 [km] is est- ‘mated with the SAI, as shown by Kippl and Thuro (2013) for dise cutters (Eq, 134.3) and scrapers (Eq. 134.4): Sepia) = 288 + exp(—0.004- (SAL, ~ 1.640) (134.3) Seas) = 271 + exp(—0.004 - (SAI,,, — 1.634)) (134.4) For disc cutters, S44.) is corrected by the tip width bse. {inm] of the cutter ring. With reference to the most common, value for sx of 19 mm, the correction factor fy is calculated by (Eq. 134.5): bse mt (sas) For scrapers, Sy) is comected by the actual penetration rate py) [mmvrot] of the individual scrapers. Képp! and F. Képpl et al ‘Thuro (2013) subdivide this step with two separate Factors fy and f,, considering the expected penetration rate pay) [mm/ rot] and the number of identical scrapers kse per cutting track. Both factors indirectly cover the actual penetration rate yc) Of the individual scrapers, since pay is split between all identical scrapers on a cutting track (ksc) ‘depending on their angular distance 8, [°]. The verification ‘of the model proved it to be more appropriate to directly ‘consider py) for correction in Eq. 134.7. Assuming a symmetrical cutter head layout, the actual Penetration rate pi») [mm/rot] of a scraper can be roughly estimated by Eq, 134.6: Paiz) (134.6) (134.7) The expected values for the cutting distance S.,y for dise ‘cutters and scrapers are calculated by multiplication of the basic value Sh With the respective factors fy, oF fy- The ‘expected value for the cutting distance S..¢. is valid within a defined range of additional influencing factors on the wear of the cutting tools which were qualified, but not quantified in the data analysis. A description of these factors and the respective range is given by Képpl and Thuro (2013). 134,2,3 Estimation of the Maintenance Stops ! For the prognosis process the maintenance stops 1 are assigned with a whole-number index k in ascending order beginning at the start ofthe tunnel. The chainage La of the stops Iu, for replacement of cutting tools over the tunnel axis depends on the advance distance Lig), [ml achieved between the stops. The maximum value Ljmaa [nn] of Lg is defined by the wear limits of the tools. Stating with unworn tools, the maximum achievable advance stance Liga) {m] for each individual cutting tool is estimated by Eq, 134.8 using the expected value of the penetration rate pay) [mmirot] and the track radius n, [um] Poi * 1.000 Lice = (134.8) Considering all cutting tools on the cutter head, the maximum advance distance Lay Of the TBM is given by the minimum value out of all values for Lica max) = mim (Lica)) (1349)134 _Empiccal Cutting Tool Wear Prognosis, For the planning of the actual advance distance, Lia) ean be selected lower or equal t0 Limuxit) Without compromising the wear limits of the cutting tools: Lay S Eman) (134.10) Within the section Ly) each tool performs the partial cutting distance sya) {km}, which is calculated using the actual penetration rate py) [mmv/rot] over Lyay? Lay 22-1 Pa) 1.000 (134.11) Sa) Considering the expected value for the cutting distance Scouy [km], the partial uilization factor eq) of each cuting (ool over Lia) is calculated by: (134.12) ‘The advance sections Lyx) are strung together consecu- tively from the start of the tunnel. The actual chainage Lac: ‘tw [m] of each maintenance stop la) is ealculated by accu- ‘mulation of all sections Liqy excavated until ly i Lrscs) = > Lae (134.13) ‘The cumulative uilization factor euau) Of each tool at stop I is calculated by accumulation of the partial utili- zation factors ea) in the advance sections Ly; (134.14) Catting tools may go through more than one advance section Lyy),S0the lower constraint of the sum in Eg 134.148, set at Lygo Which equals the chainage Ly yay ofthe stop lay, ‘here the individual tool was assembled on the cutter head ‘The process in Eqs. 134.8-134.14 supposes, that the maintenance stops x) and usr) are located in the same geotechnical section, represented by the expected values for Scete and Pec in Eqs. 1348 and 134.12, In case Laasty crosses a boundary between geotechnical sections, the pro- cess in Eqs. 134.8-134.14 needs be subdivided, consid- ering different values for s..c2) and Pa.) in the legs of the different geotechnical sections. 134.24 Estimation of the Tool Changes nc Starting at a given maintenance stop Ia) the process in Eqs. 134.8-134.10 allows to plan the advance distance Ly, 755 +110 the next stop Hyer) The chainage Lyerasty of Kaen) and the cumulative utilization factor e.sequety feSult from Bgs. 134.11-134.14, using Lyxery The calculation of the maximum achievable advance dis- tance La [mn Ba, 134.8 stating from the stop I assumes inwor tools, independent ofthe atual cumulative wilization factor enay- Consequently Eq. 134.14 may produce values fore gauss) #eatr than | for individual tools, For these tools the wear limit would be exceeded during the planned advance distance Lia. leading to potential damage due to excessive wear. Therefore they have tobe changed atthe actual stop Ii. in order to enable the selected advance distance Liasty Accordingly the general criterion for tool changes during a maintenance stop Ta, can be formulated a eae) > (134.15) Following the criterion in Eq. 134.15, the number of cutting tools nya to be changed during each maintenance slop Tay can be accumulated overall cutting tools on the cutter head by: 4a) = Doeeaaies) > | (134.16) The prognosis process focuses on planning ofthe advance distances Lyje1. The criterion for replacement of cutting tools in Eq, 134.15 is designed to enable the selected value for Lg, +1» Consequently the criterion may also effect preventive tool ‘changes at values of ay lower than 1. This relation reflects the higher impact of the stops Ig, on TBM advance compared 10 niu Ht aso implies that any change in the advance dis- tances Ligs1 effects on na) and vice versa 1342.5 Adaption Algorithm ‘The prognosis model as detailed in Eqs. 134.1~134.16 does not consider the given conditions of the project regarding accessibility of the excavation chamber. In onder to ensure realistic results it is mandatory to check these conditions at each planned chainage Li saa OF the maintenance stops I In ease the chainage Lissa) Of a stop In) is located in a ‘rtieal section, the model allows for adaption by: © Vaiation of the basic data (e.g. layout of the tools or penetration rate p) Selection of different values for Lig) in Bq. 134.10. ‘The variation of theses parameters effects the chainage of all maintenance stops Ij. It is therefore recommended to do the adaption in small iterative steps. The same process may also be used to analyze the propagation of variances of the basic data in the model by developing different prognosis756 134.3 Conclusion ‘The prognosis model provides a comprehensive method to estimate the required maintenance stops I, for Hydroshield ‘TBM in soft ground. This method can be effectively used to reduce the impact of unplanned demand for TBM mainte- nance, especially in projects with complex geotechnical conditions and in densely populated areas. Thus the overall, impact of this tunneling method on the project environment may be reduced (o a minimum already in the planning sta ‘The prognosis elaborated in the planning stage of a pro- ject requires follow up during the advance phase, Primarily to validate the assumptions in the prognosis, but also for comprehensive documentation of additional data for devel- ‘opment of the prognosis model, as for example demonstrated by Wendl et al. (2010), Dallmann et al, 2013) and Holl- ‘mann et al. (2013 F. 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