Design and optimization of layout patterns for rock TBM cutterheads

This paper presents a geomechanical framework for designing and optimizing layout patterns of cutterheads for rock Tunnel Boring Machines (TBMs), aiming to enhance their engineering performance. By examining the forces and moments exerted by rock, the study addresses geometric constraints associated with cutter boxes in key regions of the cutterhead, including the center, face, and gage areas, as well as the three-dimensional effects of cutterhead curvature on the geometric constraints of the back of the cutter boxes in the gage area. Novel formulas are proposed for determining the center points of cutter boxes and calculating both the minimum angular spacing and distance spacing between consecutive cutter boxes along a spiral path. The paper outlines an optimized layout design process for four cutterhead configurations: random, random paired, radial, and double spiral designs. Examples are provided to illustrate the results of applying these designs. The findings underscore the efficacy of the proposed methods in achieving a uniform and symmetrical distribution of cutters and buckets on the cutterhead surface. This approach effectively eliminates boundary overlap and minimizes unbalanced forces and moments. From a geomechanical standpoint, this framework offers a robust strategy for enhancing the performance and reliability of TBM cutterheads in rock tunneling operations.