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] |
| Copyright of Journal of Failure Analysis & Prevention is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
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| Header | DbId: egs DbLabel: Engineering Source An: 190408909 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Failure Analysis and Crack Propagation Mechanism Study of Fractured Cutter Ring in Shield TBM Disk Cutters. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Liu%2C+Hongbin%22">Liu, Hongbin</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Li%2C+Jun%22">Li, Jun</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> 3014821386@qq.com</i><br /><searchLink fieldCode="AR" term="%22He%2C+Tao%22">He, Tao</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liu%2C+Hanjun%22">Liu, Hanjun</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhou%2C+Changwei%22">Zhou, Changwei</searchLink><relatesTo>1,2</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Journal+of+Failure+Analysis+%26+Prevention%22">Journal of Failure Analysis & Prevention</searchLink>. Dec2025, Vol. 25 Issue 6, p3093-3108. 16p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Failure+analysis%22">Failure analysis</searchLink><br /><searchLink fieldCode="DE" term="%22Crack+propagation%22">Crack propagation</searchLink><br /><searchLink fieldCode="DE" term="%22Radial+stresses%22">Radial stresses</searchLink><br /><searchLink fieldCode="DE" term="%22Cutting+tools%22">Cutting tools</searchLink><br /><searchLink fieldCode="DE" term="%22Tunnel+design+%26+construction%22">Tunnel design & construction</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: 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] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Journal of Failure Analysis & Prevention is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1007/s11668-025-02332-2 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 16 StartPage: 3093 Subjects: – SubjectFull: Failure analysis Type: general – SubjectFull: Crack propagation Type: general – SubjectFull: Radial stresses Type: general – SubjectFull: Cutting tools Type: general – SubjectFull: Tunnel design & construction Type: general Titles: – TitleFull: Failure Analysis and Crack Propagation Mechanism Study of Fractured Cutter Ring in Shield TBM Disk Cutters. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Liu, Hongbin – PersonEntity: Name: NameFull: Li, Jun – PersonEntity: Name: NameFull: He, Tao – PersonEntity: Name: NameFull: Liu, Hanjun – PersonEntity: Name: NameFull: Zhou, Changwei IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 12 Text: Dec2025 Type: published Y: 2025 Identifiers: – Type: issn-print Value: 15477029 Numbering: – Type: volume Value: 25 – Type: issue Value: 6 Titles: – TitleFull: Journal of Failure Analysis & Prevention Type: main |
| ResultId | 1 |
