Full-scale test of disc cutter rotary cutting in TBM tunnelling: a case study of Mawan granite in Shenzhen, China

Understanding the distribution of cutting force provides a foundation for the design and optimization of cutterhead layout. The simulation of rotary cutting with a large cutting radius remains a challenge for laboratory tests. In this study, taking the driving condition of the Mawan Tunnel located in the Guangdong-Hong Kong-Macao Greater Bay Area as a case study, a full-scale rotary cutting platform with large cutting radius was used to investigate the rock-breaking effects. Rotary cutting with cutting depths of 1–8 mm and cutting radii of 200–1400 mm were carried out on the granite testing platform using a 19-in disc cutter. The normal force, rolling force, and side force during the cutting process were systematically monitored. Moreover, the time–frequency characteristics of the rock breaking process and the effects of cutting depth, cutting radius and stress state on the average and peak loads were investigated. The results show that the average normal force and rolling force increased with increasing cutting depth, while the side force was less affected by cutting depth through the Boltzman model analysis. The average normal force and rolling force were not significantly affected by the cutting radius, but the average side force decreased as a power function with increasing cutting radius, and showed a stable side force when the installation radius exceeded 1000 mm. The dominant frequency of the cutting force was 0–1.2 Hz, exhibiting notable low-frequency characteristics. Additionally, the ratio of peak to average (RPA) with respect to triaxial cutting force demonstrated an increase with the growth of cutting depth, while RPA in terms of side force exhibited a corresponding growth with the increasing cutting radius. In particular, the cutting force characteristics of the cutterhead obtained in this study can inform the layout of disc cutters and real-life TBM operations, thereby avoiding severe overloading of internal disc cutters.