Numerical Simulation of Mechanical Response of Tunnel Breakage in the Construction of Cross Passages by Mechanical Excavation Method Using Flat-Face Cutterhead

Mechanical construction has gradually been applied in cross passages of metro lines, but more mechanical mechanisms should be revealed. The section between Jingrong Street Station and Kunjia Road Station in Suzhou Metro Line 11 adopts a mechanical construction method to construct a cross passage. A novel flat-face cutterhead, which is different from curved cutter head is first used to cut and break the main tunnel in construction of cross passage. Based on the background of practical engineering, the finite element method was applied to simulate the breaking process of the main tunnel to explore the dynamic variation in the mechanical response of the segments cut by the flat-face cutterhead. The results indicate that the maximum vertical displacement caused by cutting mainly concentrates on the top of the fully cut rings. The maximum horizontal displacement occurs at the waist on the side of the tunnel portal in the semi-cut rings. The axial force level inside both types of segment rings reaches its peak after the tunnel is formed. The maximum axial force exists at the bottom and top of the fully cut ring and semi-cut ring, respectively. The change in the displacement around the portal is not substantial before the third stage, and it begins to increase significantly from the moment the concrete at the portal is penetrated. The existence of the pre-support system effectively controls the displacement of the third and fourth fully cut rings. Emphasis should be placed on reinforcing the soil near the top and waist of the second to fifth rings. The findings demonstrate that the application of flat-face cutterhead in mechanical construction of cross passages is safe, reliable, and efficient, and can provide valuable suggestions for further cutting parameters and soil reinforcement as well.