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Failure Analysis and Crack Propagation Mechanism Study of Fractured Cutter Ring in Shield TBM Disk Cutters.

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Title: Failure Analysis and Crack Propagation Mechanism Study of Fractured Cutter Ring in Shield TBM Disk Cutters.
Authors: Liu, Hongbin1,2 (AUTHOR), Li, Jun1,2 (AUTHOR) 3014821386@qq.com, He, Tao1,2 (AUTHOR), Liu, Hanjun1,2 (AUTHOR), Zhou, Changwei1,2 (AUTHOR)
Source: Journal of Failure Analysis & Prevention. Dec2025, Vol. 25 Issue 6, p3093-3108. 16p.
Subjects: Failure analysis, Crack propagation, Radial stresses, Cutting tools, Tunnel design & construction
Abstract: In response to the fracture case of a center double disk cutter ring in a shield tunneling project in Guangdong, a systematic failure analysis was conducted and its crack propagation mechanism was revealed. Through macroscopic morphology observation, tunneling parameter analysis, material property testing, and fractographic analysis, it was confirmed that the root cause of the fracture was severe eccentric wear induced by bearing seizure, thereby excluding the influence of the base material performance. Fractographic analysis indicated that all cracks originated in the blade edge region, exhibiting three initiation modes: defect-induced, fatigue, and brittle intergranular, while the final fracture zones all displayed overload characteristics. Simulation results based on the Extended Finite Element Method (XFEM) demonstrated that radial force overload was the dominant factor driving crack propagation: Existing cracks began to propagate at 1.52 times the radial force, extended stably with increasing load, and ultimately penetrated approximately 70% of the cutter ring thickness in the vertical direction at 4.8 times overload, with the propagation path showing high consistency with the macroscopic fracture morphology. The study reconstructed the failure causal chain of the disk cutter from bearing seizure to ring fracture and accordingly, proposed a four-level progressive prevention and control strategy, providing theoretical support for the reliability design and intelligent operation and maintenance of shield disk cutters. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:In response to the fracture case of a center double disk cutter ring in a shield tunneling project in Guangdong, a systematic failure analysis was conducted and its crack propagation mechanism was revealed. Through macroscopic morphology observation, tunneling parameter analysis, material property testing, and fractographic analysis, it was confirmed that the root cause of the fracture was severe eccentric wear induced by bearing seizure, thereby excluding the influence of the base material performance. Fractographic analysis indicated that all cracks originated in the blade edge region, exhibiting three initiation modes: defect-induced, fatigue, and brittle intergranular, while the final fracture zones all displayed overload characteristics. Simulation results based on the Extended Finite Element Method (XFEM) demonstrated that radial force overload was the dominant factor driving crack propagation: Existing cracks began to propagate at 1.52 times the radial force, extended stably with increasing load, and ultimately penetrated approximately 70% of the cutter ring thickness in the vertical direction at 4.8 times overload, with the propagation path showing high consistency with the macroscopic fracture morphology. The study reconstructed the failure causal chain of the disk cutter from bearing seizure to ring fracture and accordingly, proposed a four-level progressive prevention and control strategy, providing theoretical support for the reliability design and intelligent operation and maintenance of shield disk cutters. [ABSTRACT FROM AUTHOR]
ISSN:15477029
DOI:10.1007/s11668-025-02332-2