Feasibility Study for the Remanufacturing of H13 Steel Heat-Treated TBM Disc Cutter Rings with Uniform Wear Failure Using GMAW

Abstract

Given that the heat treatment states of the base metal have a great influence on the surfacing repair layer, this paper carried out a feasibility study for the remanufacturing of the failed cutter rings of TBM disc cutters with uniform wear (hereinafter referred to as normally-worn ring) using the gas metal arc welding technology (GMAW). Firstly, this paper developed a heat treatment process route for H13 steel cutter rings. Secondly, the heat treatment process is numerically analyzed based on the developed route, and the rationality of the route is verified from the distribution characteristics of temperature, phase, and stress fields. Subsequently, heat treatment tests were carried out, and the physical and mechanical properties of the base metal samples prepared under laboratory conditions were evaluated respectively and systematically. Based on the comprehensive performance evaluation value calculated by the weighted comparative analysis method, it was clear that the comprehensive performance of the quenched base metal samples was 7.6% higher than that of the engineering cutter ring interior. Therefore, it is reasonable to replace the failed engineering cutter rings repaired under laboratory conditions with the prepared samples as economical alternatives. Finally, the remanufacturing of the base metal samples using GMAW was carried out, and then the remanufacturing performance of the base metal samples was analyzed. The study concluded that the comprehensive performance of the surfacing repair layer was slightly lower than that of the engineering cutter ring edge (4.1%), thus proving that the idea of surfacing remanufacturing of the normally-worn ring proposed in this paper was basically feasible.

Investigation of Disc Cutter Wear in Tunnel-Boring Machines (TBMs): Integration of Photogrammetry, Measurement with a Caliper, Weighing, and Macroscopic Visual Inspection

“…Due to its favorable mechanical properties, hot-work tool steel is often used for the production of disc cutter rings [4,11,27,[29][30][31]. This steel grade has high hardness, toughness, and abrasion resistance and is therefore well suited to the demanding geological and geotechnical conditions of mechanized rock mining.…”

“…This steel grade has high hardness, toughness, and abrasion resistance and is therefore well suited to the demanding geological and geotechnical conditions of mechanized rock mining. Its high material strength with high fracture toughness enables the steel cutter ring to withstand the high contact stresses and abrasion forces that occur during the cutting process [4,29].…”

“…In recent studies in the literature, various strategies have been investigated to improve the performance and durability of disc cutters under different material and manufacturing conditions. Studies by Zhang et al [4] and Hu et al [5] focus on the design of disc cutters, their material composition, and processing techniques to improve wear resistance. These studies underline the influence of factors such as the diameter, shape, and material composition of disc cutters on wear resistance and provide valuable insights to optimize their performance in difficult operating environments.…”

“…These studies underline the influence of factors such as the diameter, shape, and material composition of disc cutters on wear resistance and provide valuable insights to optimize their performance in difficult operating environments. Zhang et al [4] also investigated the remanufacturing of H13 steel disc cutters and presented advances in repair techniques. They point out the advantages of remanufacturing technology in improving energy and material utilization, which ultimately increases cutting efficiency and reduces production costs.…”