Innovative Design of a Cutter Disc Wear Measurement Device: A Simulation Approac

The wear of cutter discs in Tunnel Boring Machines (TBMs) is a critical factor influencing tunneling efficiency and cost-effectiveness. As TBMs operate in diverse geological conditions, the performance and longevity of cutter discs directly impact project productivity and expenses. Understanding the wear mechanisms and operational parameters affecting cutter disc degradation is essential for optimizing tunneling operations. This study aims to design and construct a full-scale testing device that replicates real-world tunneling conditions to evaluate cutter disc wear. The testing system will analyze the effects of key operational factors, including vertical force, rotational force, and revolutions per minute (RPM), on cutter disc wear when interacting with crushed rock. By systematically varying these parameters under controlled conditions, the study seeks to establish correlations between wear rates and influencing factors such as applied forces, disc travel length, and rotational characteristics. A structured experimental approach will be employed to measure wear progression, and statistical analyses will be used to interpret data trends. The findings will help identify optimal operational ranges that minimize cutter disc wear, enhancing TBM efficiency and reducing maintenance costs. Moreover, the study aims to develop a mathematical model correlating cutter disc weight reduction with specific operational parameters, particularly vertical and rotational forces (Fn and Fr). This model will provide a predictive framework for estimating cutter disc wear during the tunnel design phase, enabling engineers to make data-driven decisions that enhance TBM performance and longevity. Ultimately, by optimizing cutter disc usage, the study contributes to cost savings, increased reliability, and improved sustainability in mechanized tunneling projects