Sandy pebble strata, characterized by high pebble content, high uniaxial compressive strength (UCS) of pebbles, poorly-sorted grain size distribution, and low flowability, often induce muck accumulation, cutterhead clogging, and chamber caking during earth pressure balance (EPB) shield tunneling, thereby reducing construction efficiency and compromising safety. Existing studies, predominantly relying on macroscopic indicators, often fail to elucidate the mesoscopic particle transport behaviors and the synergistic mechanism of the cutterhead-agitator system. This study develops a full-scale, three-dimensional finite difference method-discrete element method (FDM–DEM) coupled model to simulate particle transport within the cutterhead and soil chamber, to systematically reveal the transport mechanisms and guide equipment optimization. Results indicate that: (1) the soil chamber exhibits a “core–ring” dual-flow structure, characterized by a low-velocity “dead-zone column” at the center and a high-velocity annular channel at the periphery, attributed to the limited opening ratio in the central area and insufficient agitator coverage; (2) a “barrier–channel–dead-zone column” triple-control mechanism is proposed to explain the constraints imposed by energy barriers, geometric confinement, and cascade migration on particle transport; and (3) a synergistic optimization strategy is proposed, which includes increasing the opening ratio in the cutterhead’s central region, installing vertical agitators at the chamber center, and relocating the inner-ring agitator to R = 1.8 m. These findings provide significant theoretical insights for understanding muck transport behaviors and optimizing EPB shield design in sandy pebble strata.
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