Dimensional consistency-based modeling of disc cutter wear in hard rock tunneling utilizing integrated multivariate analysis

Disc cutter wear significantly impacts the stable and safe operation of Tunnel Boring Machines (TBMs) in hard rock tunneling, necessitating integrated analysis of its numerous related variables. This study began by examining multiple mechanisms related to disc cutter wear, comprehensively summarizing the key factors of wear mechanisms and converting them into four categories of practical engineering variables: load, yield property, relative motion distance, and hard mineral particle content. The correlation of individual variables with wear behavior was accurately assessed by controlling the stability of other variables. Especially, to account for the combined effects of operational and geological strength variables on load-type variables, the concept of dynamic cutting pressure was introduced, which showed a stronger correlation with wear behavior than that of individual variables alone. Following the principle of dimensional consistency, an integrated wear prediction model was developed. Validation with data from another tunneling project confirmed the model's accuracy and applicability. This study provides an accurate wear prediction method utilizing readily accessible practical engineering variables during construction, thereby offering a crucial reference for determining the optimal timing for disc cutter replacement and enhancing TBM operational reliability.