Search Results (8)

The CERCHAR abrasivity test is a widely used index test in earth and subsurface works, delivering numerical values for abrasion that are critical to the selection of excavation tools, TBM performance or cost and project schedule estimates. The test evaluates the wear of the tip of a standardized metal pin after a scratch test on a rock surface. However, excavatability is not considered in this test. The present study presents an approach to assessing the material removal of a rock specimen due to the scratching action of a steel pin. The concept is tested for a broad range of sedimentary, metamorphic and igneous rocks. The volume of removed rock material is determined by measuring the width of the scratch groove and assuming an idealized trapezoid geometry. The CAI and volumetric removal are used to calculate the CERCHAR abrasivity ratio (CAR), and the results are in good agreement with those from the literature where specialized equipment was used. A classification scheme to estimate the excavatability of rock based on the CAI in combination with the material removal of a rock specimen is introduced. Based on the amount of material removed and the wear on the pin, an estimate can be made as to whether the excavation is likely to be economical in terms of time and material costs. The approach does not require additional testing, but rather makes use of the inherent geometry of the steel pin and the scratch groove on the rock specimen. The approach can be implemented as a complementary analysis to the existing CERCHAR test with little additional effort. Full article

This study aimed to develop predictive models for rock hardness and abrasivity based on hyperspectral imaging data, providing valuable information without interrupting the mining processes. The data collection stage first involved scanning 159 rock samples collected from 6 different blasted rock piles using visible and near-infrared (VNIR) and short-wave infrared (SWIR) sensors. The hardness and abrasivity of the samples were then determined through Leeb rebound hardness (LRH) and Cerchar abrasivity index (CAI) tests, respectively. The data preprocessing involved radiometric correction, background removal, and staking VNIR and SWIR images. An integrated approach based on K-means clustering and the band ratio concept was employed for feature extraction, resulting in 28 band-ratio-based features. Afterward, the random forest regressor (RFR) algorithm was employed to develop predictive models for rock hardness and abrasivity separately. The performance assessment showed that the developed models can estimate rock hardness and abrasivity of unseen data with R² scores of 0.74 and 0.79, respectively, with the most influential features located mainly within the SWIR region. The results indicate that integrated hyperspectral data and RFR technique have strong potential for practical and efficient rock hardness and abrasivity characterization during mining processes. Full article

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. Full article

The construction environment of deep rock tunnels is complex, and effectively enhancing tunnel boring machine (TBM) tunneling efficiency is paramount. Increasing rock-breaking efficiency and minimizing cutter consumption are essential strategies for improving TBM tunneling efficiency. Selecting suitable tunneling parameters is crucial for enhancing rock-breaking efficiency and reducing cutter consumption. Existing research on the optimization of the ratio of maximum cutter spacing to penetration (S_max/P) based on field-measured data is limited, and few studies compare and analyze the relationship between SE, CI, and the S_max/P ratio separately. Consequently, this study determined optimal tunneling parameters for various types of surrounding rock and construction environments, aiming to more accurately optimize TBM tunneling performance during construction processes based on on-site construction data. This study conducted a comparative analysis of specific energy (SE) and the coarseness index (CI). Under both working conditions, the quadratic fitting coefficients of the CI are 4.2% and 10.6% higher than those of the SE, respectively, with the CI selected to represent the particle size distribution of rock chips. Finally, taking into account both the correlations between the CI and the ratio of maximum cutter spacing to penetration (S_max/P), as well as cutter consumption and the S_max/P ratio, an optimization method for the TBM tunneling parameter was established under both dry and saturated conditions. The research findings indicate that cutter consumption exhibits an exponential increase with a higher rock Cerchar Abrasivity Index (CAI); it initially decreases as the S_max/P ratio increases and subsequently increases in both dry and saturated conditions. Instead, the CI demonstrates an initial increase and subsequent decrease as the S_max/P ratio increases. Maximizing rock-breaking efficiency and minimizing cutter consumption are crucial for improving tunneling performance. In saturated conditions, the corresponding optimal S_max/P ratio ranges are 7.055–8.319 for soft rock, 8.606–8.931 for medium–hard rock, and 13.50–14.00 for hard rock, and these optimal ranges under dry conditions are 8.495–9.457, 10.972–12.169, and 16.5–17.5 for the same rock types. This study provides optimal S_max/P ratio ranges for TBM tunneling, thereby significantly enhancing tunneling efficiency. Full article

The brittleness of rock is known to be an important property that affects the fragmentation characteristics of rock in mechanized rock cutting. As the interaction between the cutting tool and the rock (i.e., cutter forces, cutting efficiency, s/p ratio, and abrasivity) during mechanical rock cutting is strongly influenced by the characteristics of rock fragmentation, the cutting tools (i.e., disc cutter and pick cutter) experience different cutting behaviors depending on the rock brittleness. In this study, the relationships between the rock brittleness and the abrasivity of rock, and the cutting efficiency of a Tunnel Boring Machine (TBM) disc cutter were investigated for Korean rock types. The brittleness was calculated by the mathematical relations between the uniaxial compressive and Brazilian tensile strengths of the rock. The cutting efficiency and abrasivity were evaluated by the cutter forces and specific energy from the linear cutting machine (LCM) test and the Cerchar abrasivity index (CAI) test, respectively. The results show that rock brittleness is significantly correlated with cutting efficiency and CAI values. Consequently, some prediction models for cutter forces, specific energy, and the CAI were proposed as functions of the rock brittleness. Full article

The use of ornamental stones has a historical value that makes them strategically precious in Italy; marble can offer high performance in architectural applications, even though the variability of the rock mass requires detailed studies to optimize the exploitation techniques and reduce waste. Italy is world famous for its marble, which is extracted mainly through chainsaw cutting machines, which are currently used intensively due to their high-safety working conditions compared to alternative techniques and for their great versatility, especially in underground applications. Although this cutting technique is well-rooted, an uncommon problem of tool wear was found in the quarry under study, which strongly affected productivity. A series of laboratory test were carried out to estimate the wear potential of the rock and the suitability of the tools. The Cerchar abrasivity test highlighted a mean wear potential for the marble of 2.77, while microhardness outcomes pointed out the presence of quartz veins in the tested material (values over 10,000 MPa). Finally, additives typically used in the conditioning process of EPB machines in tunneling were tested with the purpose of reducing the extent of wear. A reduction of about 50% in the wear (in terms of weight lost) was obtained for a moisture content of 9%. Full article

The sandstones with a laminated structure are common building materials. Lamination is macroscopically expressed as colour and grain size variations observed both in the deposit and within individual beds; therefore, the properties of such sandstones are diverse depending on the spatial distribution of the binding mass and framework components. For the terrestrial sandstones of different genesis, four types of laminae have been distinguished based on petrographic studies. They have a siliceous binder or a mixed ferruginous–siliceous–argillaceous binder with different proportions of these components. In laminae of types I–III, the grain framework is built mainly of quartz grains, and in type IV, it is accompanied by numerous lithoclasts and feldspars. Knoop hardness and CERCHAR abrasivity were tested in each lamina variety, and the results were correlated with the equivalent quartz content and the longitudinal ultrasonic wave velocity measured perpendicular and parallel to the lamination. The proposed research methodology was not used in previous studies on terrestrial laminated sandstones. The results explain a strong dependence between mineral composition, structure of laminae, and technical parameters of rocks. The knowledge of this relationship facilitates the selection of rocks that meet the relevant technical requirements and helps to optimally manage the resources of sandstone deposits. Full article

The abrasiveness of rocks significantly influences the wear endured by excavation tools in tunnel boring machines (TBMs). In slurry shield TBMs, wear occurs not only in excavation tools but also in discharge pipes and pumps of slurry transport systems. To explore this phenomenon, this study investigated the effect of rock abrasiveness on the wear of both disc cutters and slurry discharge pipes in slurry shield TBMs. The radial wear of disc cutters and the thickness of slurry discharge pipes were measured and monitored at a TBM site in Singapore. The relationship between the weathering grade of Bukit Timah granite and the wear coefficient of disc cutters was analysed, and a correlation between the Cerchar Abrasivity Index values and the wear coefficient of 19 inch disc cutters was suggested. Additionally, the average wear rates of slurry discharge pipes used for Bukit Timah granite were determined based on the pipe thickness measurements. The wear rates of weathering grades G(I) to G(IV) of Bukit Timah granite were observed to be highly similar to each other, whereas the wear rates of G(V) grade and mixed ground were 1.55 times higher than those of the G(I) to G(IV) grades. The correlation between the slurry discharge velocity and the wear rate in slurry discharge pipes was thus derived. The accurate assessment of the effect of rock abrasiveness on both the wear of disc cutters and the wear rate in slurry discharge pipes, investigated in this paper, will highlight the need for efficient maintenance of the excavation tools in TBMs and encourage the development of various equipment wear prevention measures in order to minimize overall construction costs and time. Full article