Dynamic load distribution and torque energy consumption measurement of full-section hard rock shaft boring machine cutterheads: A comparative simulation study

• Novel measurement framework: A dynamic simulation-based approach integrating 3D modeling and Adams platform quantifies torque, energy consumption, and triaxial forces (vertical/lateral/rolling) across three cutterhead configurations (conical, composite, planar). • Load distribution metrics: Planar cutterheads exhibit superior load uniformity, outperforming conical and composite designs in stress homogeneity. • Thrust-energy tradeoff: Conical cutterheads achieve 7% lower thrust than theoretical predictions with 30% higher rock-breaking efficiency, while planar designs reduce energy consumption by 19% despite longer excavation time. • Equivalent time method: Proposed metric enables direct comparison of energy efficiency per unit volume (conical: 47.5 MJ/m³; composite: 51.5 MJ/m³; planar: 37.6 MJ/m³), linking torque dynamics to operational costs. • Data-driven terrain adaptation: The conical cutterhead is suitable for hard rock/composite formations; Composite cutterhead is suitable for composite formations with high water pressure; Flat cutterhead suitable for soft rock/sandy soil layers. The structural configuration of cutterheads plays a critical role in determining torque dynamics, energy efficiency, and load distribution in full-section shaft boring machines. This study quantitatively evaluates three mainstream cutterhead designs (conical, conical-planar composite, and planar) through an integrated measurement framework combining 3D modeling and Adams dynamic simulations. A novel equivalent time method is proposed to assess energy consumption characteristics, enabling systematic comparisons of load distributions and torque variations under realistic rock-breaking conditions. Dynamic simulations reveal that: (1) Hob cutting forces (vertical, lateral, rolling) positively correlate with installation radius. Vertical and lateral forces share identical trends. Conical and composite cutterhead positive hobs exhibit increasing fluctuations with radius, while planar cutterhead hobs show superior load uniformity.(2) Rolling forces for all straight hobs: 50-100kN, peaking on conical cutterheads. (3) Conical designs achieve the highest rock-breaking efficiency (30% faster than planar types) despite requiring 7% lower thrust than theoretical predictions. Geological adaptation analysis further establishes data-driven selection criteria: conical cutterheads perform optimally in unstable hard rock and aquatic formations, composite designs excel in high-pressure and transitional strata, while planar configurations are ideal for soft rock and clay environments. These findings provide measurable benchmarks for cutterhead optimization, advancing precision in excavation system design and energy consumption management.