Evaluation of TBM Cutter Wear in Granite and Developing a Cutter Life Prediction Model for Face Cutters Based on Field Data: A Case Study

Disc cutter wear has emerged as a critical concern impacting the efficiency and cost budgets of TBMs (tunnel boring machines). Through statistical analysis of field data on cutter wear in a TBM tunnel, this study explores the wear rules of different types of disc cutters in granite. Grey sensitivity analysis is employed to investigate the sensitivity between the cutter ring wear rate of face cutters and two types of cutter wear influence parameters. Subsequently, reasonable parameters are selected to develop a new cutter life prediction model for face cutters. The results show that, with increases in the installation radius, the accumulated wear extent shows a linearly increasing trend for both the center and the face cutter, while it first increases and then decreases for gauge cutters, and the accumulated replacement number shows a linear growth trend for face cutters. The accumulated wear extent of the average single cutter position of gauge cutters is about 3 times that of face cutters and 7 times that of center cutters; the number of replaced cutter rings of the average single cutter position for gauge cutters is about 3-4 times that for center cutters and face cutters; and the average utilization rate of gauge cutters is the highest (80.97%). The cutter ring wear rate of face cutters is the most sensitive to three intact rock parameters (uniaxial compressive strength (UCS), Cerchar abrasion index (CAI), and equivalent quartz content (EQC)) and two TBM tunnelling parameters (cutterhead thrust (F) and cutterhead rotational speed (RPM)). Finally, a new cutter life prediction model (R2 = 0.964) for face cutters is developed based on F, UCS, and RPM. The research results can provide a certain theoretical basis for cutter wear and cutter life prediction for the face cutters of TBM projects in similar geological conditions and TBM specifications.