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<p>Accurately evaluating cutting efficiency and intelligently optimizing cutter spacing of tunnel boring machine (TBM) in dark, dusty working environments has been challenging. In such an environment, traditional methods such as manual weighing and photogrammetry are ineffective. A three-dimensional (3D) digitization reconstruction method was proposed to achieve precise capture of rock surface morphology, and assessment of cutting efficiency through measurement of cutting volume. Specifically, the linear laser measurement system and the Python-driven 3D reconstruction algorithm were used to digitally reconstruct the micro-scale fragmentation characteristics of tunnel faces. The rock ridge characteristics, specific cutting energy, and optimum cutter spacing could be intelligently acquired. Furthermore, a novel indicator, termed as new specific surface area (increased surface area per unit mass of fragmented rock), was introduced to characterize cutting efficiency. The minimum new specific surface area denoted optimum cutting efficiency. Moreover, the research investigated the effects of cutter spacing (<i>s</i>) and cutting depth (<i>p</i>) on the rock-breaking performance of disc cutters. The research results showed that the novel index demonstrated a robust positive correlation with specific cutting energy and a negative correlation with roughness index. The crack propagation length (<i>L</i>) and the height difference (<i>d</i>) between the rock ridge and the cutting groove yielded three distinct rock fragmentation modes: under-fractured (<i>s</i> too large, <i>d</i> &gt; 0), cooperative (optimal <i>s</i>, <i>d</i> = 0), and over-fractured (<i>s</i> too small, <i>d</i> &lt; 0). The cutting efficiency, characterized by the new specific surface area, was jointly governed by the s/p ratio, reaching an optimum at a ratio of approximately 16.7. The optimum cutter spacing could be intelligently acquired based on the rock fracture angle and crack propagation length using the 3D digitization reconstruction method. The approach's accuracy and feasibility were verified through experimental results. These findings could provide a crucial perspective for the TBM digital and intelligent rock-breaking processes.</p>

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A Novel Index of Cutting Efficiency and Intelligent Cutter Spacing Optimization of TBM Based on Three-Dimensional Digitization Reconstruction Technology

  • 期刊论文

  • 发表日期：

    2026年6月30日

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  • Longchuan Deng,
  • Juanjuan Li,
  • Hailing Shi,
  • Wentao Xu,
  • Qinbin Meng,
  • Chi Zhang

摘要

Accurately evaluating cutting efficiency and intelligently optimizing cutter spacing of tunnel boring machine (TBM) in dark, dusty working environments has been challenging. In such an environment, traditional methods such as manual weighing and photogrammetry are ineffective. A three-dimensional (3D) digitization reconstruction method was proposed to achieve precise capture of rock surface morphology, and assessment of cutting efficiency through measurement of cutting volume. Specifically, the linear laser measurement system and the Python-driven 3D reconstruction algorithm were used to digitally reconstruct the micro-scale fragmentation characteristics of tunnel faces. The rock ridge characteristics, specific cutting energy, and optimum cutter spacing could be intelligently acquired. Furthermore, a novel indicator, termed as new specific surface area (increased surface area per unit mass of fragmented rock), was introduced to characterize cutting efficiency. The minimum new specific surface area denoted optimum cutting efficiency. Moreover, the research investigated the effects of cutter spacing (s) and cutting depth (p) on the rock-breaking performance of disc cutters. The research results showed that the novel index demonstrated a robust positive correlation with specific cutting energy and a negative correlation with roughness index. The crack propagation length (L) and the height difference (d) between the rock ridge and the cutting groove yielded three distinct rock fragmentation modes: under-fractured (s too large, d > 0), cooperative (optimal s, d = 0), and over-fractured (s too small, d < 0). The cutting efficiency, characterized by the new specific surface area, was jointly governed by the s/p ratio, reaching an optimum at a ratio of approximately 16.7. The optimum cutter spacing could be intelligently acquired based on the rock fracture angle and crack propagation length using the 3D digitization reconstruction method. The approach's accuracy and feasibility were verified through experimental results. These findings could provide a crucial perspective for the TBM digital and intelligent rock-breaking processes.