Effects of Blade Speed on Microstructure and Wear Behavior in the Abrasion Value Cutter Steel (AVS) Test

Cutter wear is a critical concern in TBM tunneling, directly influencing cutter consumption and tunnel advance rate-crucial aspects for project planning and risk management. This laboratory study investigates the impact of the cutter rotational speed on wear behavior and lifespan using the Abrasion Value of Steel (AVS) test. The study employed a quartzite sandstone sample with a Cerchar Abrasivity Index (CAI) of 3.14 and H13 steel sample with 648 Vickers hardness for the AVS test. In the Experimental Design, five rotational speeds of 10, 15, 20, 25, and 30 RPMs were employed and their impacts were explored. Results revealed a 147.4% increase in AVS (mg) as rotational speed increased. Concurrently, quartzite sandstone abrasiveness escalated from “very abrasive” to “extremely abrasive,” while cutter life transitioned from “very low” to “extremely low”. Also, a direct linear relationship with a strong correlation between rotational speed and AVS was observed. Moreover, increasing rotational speed led to a 29% decline in the cutter life index (CLI), indicating a strong linear correlation. The study of the width of the cutter surface wear profile exhibited a relationship with angular velocities with a strong coefficient determination, increased by 27.5%. In the analysis of the disc cutter’s microstructure through a Scanning Electron Microscope (SEM), martensite as the predominant steel structure was identified. Spectroscopic analysis using Energy Dispersive Spectroscopy (EDS) revealed hard phases, including vanadium deposits and carbides. These findings contribute valuable insights into the intricate relationship between cutter rotational speeds, wear characteristics, and lifespans.