A study of rotary cutting machine (RCM) performance on Korean granite

Purpose

Despite the many advantages this type of equipment offers, there are still some major drawbacks. Linear cutting machine (LCM) cannot accurately simulate the true rock-cutting process as 1. it does not account for the circular path along which tunnel boring machine (TBM) disk cutters cut the tunnel face, 2. it does not accurately model the position of a disk cutter on the cutterhead, 3. it cannot perfectly replicate the rotational speed of a TBM. To enhance the knowledge of these issues and in order to mimic the real rock-cutting process, a new lab testing equipment was developed by Hyundai Engineering and Construction.

Design/methodology/approach

A new testing machine called rotary cutting machine (RCM) is designed to simulate the excavation process of hard-rock TBMs and includes features such as TBM cutterhead, RPM simulation, constant normal force mode and constant penetration rate mode. Two sets of tests were conducted on Hwandeung granite using different disk cutter sizes to analyze the cutting forces in various excavation modes. The results are analyzed using statistical analysis and dimensional analysis. A new model is generated using dimensional analysis, and its results are compared against the results of actual cases.

Findings

The effectiveness of the new RCM test was demonstrated in its ability to apply various modes of excavation. Initial analysis of chip size revealed that the thickness of the chips is largely dependent on the cutter spacing. Tests with varying RPM showed that an increase in RPM results in an increase in the normal force and rolling force. The cutting coefficient (CC) demonstrated a linear correlation with penetration. The optimal specific energy is achieved at an S/p ratio of around 15. However, a slightly lower S/p ratio can also be used in the design if the cutter specifications permit. A dimensional analysis was utilized to develop a new RCM model based on the results from approximately 1200 tests. The model's applicability was demonstrated through a comparison of TBM penetration data from 26 tunnel projects globally. Results indicated that the predicted penetration rates by the RCM test model were in good agreement with actual rates for the majority of cases. However, further investigation is necessary for softer rock types, which will be conducted in the future using concrete blocks.

Originality/value

The originality of the research lies in the development of Hyundai Engineering and Construction’s advanced full-scale laboratory rotary cutting machine (RCM), which accurately replicates the excavation process of hard-rock tunnel boring machines (TBMs). The study provides valuable insights into cutting forces, chip size, specific energy, RPM and excavation modes, enhancing understanding and decision-making in hard-rock excavation processes. The research also presents a new RCM model validated against TBM penetration data, demonstrating its practical applicability and predictive accuracy.