Free-face-Assisted Rock Breaking Method Based on the Multi-stage Tunnel Boring Machine (TBM) Cutterhead

In order to improve the rock breaking efficiency of hard rock tunnel boring, many innovative rock breaking methods have been proposed (e.g., the water jet cutting, the high-power laser cutting, the impact-rotary drilling, and the undercutting method). However, most of the methods are not applicable to TBMs due to some structural reasons. Aiming on this problem, a free-face-assisted rock breaking method based on the multi-stage TBM cutterhead has been proposed. Series of proof-of-concept tests includes (1) the static compression test with vertical free face and (2) the rotary cutting tests in different free surface conditions were designed and carried out. The results show that the rock breaking force and efficiency can be significantly reduced and improved, respectively, with the assistance of the free face, due to the failure of the rock close to the free face is tensile-dominated failure. The influencing distance of the free face in the radial direction is at least 330 mm which covers about 5 disk cutters. Finally, the general structure of a small two-stage cutterhead (4 m in diameter) was tentatively designed in order to provide a possible approach to apply the free-face effect to TBMs.