Investigation of the Influence of Cutter Geometry on the Cutting Forces in Soft–Hard Composite Ground by Tunnel Boring Machine Cutters

Tunnel Boring Machines (TBMs) are integral to modern underground engineering construction, offering enhanced safety and efficiency. However, TBMs often face challenges in complex geological conditions, such as composite strata, resulting in reduced advancement speed and increased cutter wear. This study investigates the rock-breaking characteristics of TBM disc cutters in composite strata through numerical simulations using the Particle Flow Code (PFC) 5.0 software. Focusing on the Jinan Metro Line 6, the research analyzes cutter forces, rock crack propagation, and the impact of cutter edge shapes on rock-breaking efficiency. The discrete element method (DEM) is employed to simulate microscopic behaviors of rocks, providing insights into crack formation, expansion, and failure. This study’s findings reveal that cutter design and operational parameters can significantly influence cutter lifespan and efficiency. By modifying cutter spacing and penetration depth, enhancing rock-breaking efficiency, and grouting softer layers, TBMs can maintain effective excavation in composite strata. The study establishes a comprehensive understanding of the interplay between TBM cutters and complex geological conditions, offering actionable strategies to enhance TBM performance and mitigate cutter damage.