Digital Twin Framework for Cutterhead Design and Assembly Process Simulation Optimization for TBM

With the rapid advancement in information technology, the digital twin and smart assembly process simulation have become an integral part of the design and manufacturing of high-precision products. However, conventional Tunnel Boring Machine (TBM) cutterhead design and on-site assembly planning remain largely experience-driven and fragmented, with limited interoperability between geological characterization, structural verification, and constructability validation. This study proposes a digital twin-driven framework for TBM cutterhead design optimization and assembly process simulation that integrates geology-aware design inputs, BIM-based information modelling, FEM-based structural assessment, and immersive virtual environments within a unified virtual–physical workflow. To ensure consistent data exchange across platforms, an IFC4.3-compliant ontology is established using a non-intrusive property-set (Pset) extension strategy to represent cutterhead components, geological parameters, FEM load cases/results, and assembly tasks. Tunnel-scale stress analysis and cutter–rock interaction modelling are used to define project-representative cutter loading envelopes, which are mapped to a high-fidelity cutterhead FEM model for iterative structural refinement. The optimized configuration is then transferred to a game-engine/VR environment to support full-scale design inspection and assembly rehearsal, followed by manufacturing and field deployment with bidirectional feedback. To validate the proposed framework, an implementation case study of a deep hard-rock tunnelling project is presented where five design iterations were tracked across BIM–FEM–VR and nine constructability issues detected and resolved prior to assembly. The results indicate that the proposed digital twin approach strengthens traceability from geology to loading to structural response, reduces localized stress concentration at critical interfaces, and improves assembly readiness for complex tunnelling projects.