A review of fatigue failure and structural design of main bearings in tunnel boring machines based on engineering practical examples

Zheng, J; Hu, S; Ji, J; Zhang, X; Tong, VC; Yin, S; Feng, K; Dong, H; Xu, L

A review of fatigue failure and structural design of main bearings in tunnel boring machines based on engineering practical examples

Zheng, J Hu, S Ji, J

Zhang, X Tong, VC Yin, S Feng, K Dong, H Xu, L

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Publisher:: PERGAMON-ELSEVIER SCIENCE LTD
Publication Type:: Journal Article
Citation:: Engineering Failure Analysis, 2024, 163
Issue Date:: 2024-09-01

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Field	Value	Language
dc.contributor.author	Zheng, J
dc.contributor.author	Hu, S
dc.contributor.author	Ji, J https://orcid.org/0000-0003-3280-5463
dc.contributor.author	Zhang, X
dc.contributor.author	Tong, VC
dc.contributor.author	Yin, S
dc.contributor.author	Feng, K
dc.contributor.author	Dong, H
dc.contributor.author	Xu, L
dc.date.accessioned	2025-02-04T00:35:10Z
dc.date.available	2025-02-04T00:35:10Z
dc.date.issued	2024-09-01
dc.identifier.citation	Engineering Failure Analysis, 2024, 163
dc.identifier.issn	1350-6307
dc.identifier.issn	1873-1961
dc.identifier.uri	http://hdl.handle.net/10453/184902
dc.description.abstract	A large-scale tunnel boring machine (TBM) is currently the most advanced equipment for underground tunnel excavation. The main bearing, carrying all the load and moment from the cutterhead, is hailed as the heart of TBMs, which connects the cutterhead and main drive system. Due to the harsh underground working conditions, the main bearing is prone to fatigue failures, which decreases its service life and could lead to extremely high replacement cost. To enhance the service life, different types of main bearings are used in TBMs depending on the geological structures. To develop a reasonable asset management and maintenance solution, it is crucial to understand the types of fatigue failures of the main bearings. This paper reviews the types and causes of fatigue failures in TBM main bearings based on practical experiences during the inspection and maintenance of over 100 sets of TBM main bearings made by different manufacturers. Fatigue failures in the TBM main bearings, including fatigue wear of components, etching cracks, peelings, rustiness, crushing damages, and bolt fractures, are mainly caused by overload, poor lubrication, foreign objects entering the main bearing interior, and non-standard operation and maintenance. The properties of different structural designs and their effects on the fatigue life of the main bearings are also presented. Furthermore, the selection of main bearings under different working conditions is discussed in order to reduce the occurrence of bearing failures. Finally, future research directions for TBM main bearings are elaborated.
dc.language	English
dc.publisher	PERGAMON-ELSEVIER SCIENCE LTD
dc.relation.ispartof	Engineering Failure Analysis
dc.relation.isbasedon	10.1016/j.engfailanal.2024.108611
dc.rights	info:eu-repo/semantics/closedAccess
dc.subject	0905 Civil Engineering, 0912 Materials Engineering, 0913 Mechanical Engineering
dc.subject.classification	Mechanical Engineering & Transports
dc.subject.classification	4005 Civil engineering
dc.subject.classification	4016 Materials engineering
dc.subject.classification	4017 Mechanical engineering
dc.title	A review of fatigue failure and structural design of main bearings in tunnel boring machines based on engineering practical examples
dc.type	Journal Article
utslib.citation.volume	163
utslib.for	0905 Civil Engineering
utslib.for	0912 Materials Engineering
utslib.for	0913 Mechanical Engineering
pubs.organisational-group	University of Technology Sydney
pubs.organisational-group	University of Technology Sydney/Faculty of Engineering and Information Technology
pubs.organisational-group	University of Technology Sydney/Faculty of Engineering and Information Technology/School of Mechanical and Mechatronic Engineering
pubs.organisational-group	University of Technology Sydney/UTS Groups
pubs.organisational-group	University of Technology Sydney/UTS Groups/Transport Research Centre (TRC)
pubs.organisational-group	University of Technology Sydney/UTS Groups/Centre for Audio, Acoustics and Vibration (CAAV)
pubs.organisational-group	University of Technology Sydney/UTS Groups/Transport Research Centre (TRC)/Transport Research Centre (TRC) Associate Members
utslib.copyright.status	closed_access	*
dc.date.updated	2025-02-04T00:35:07Z
pubs.publication-status	Published
pubs.volume	163

Abstract:

A large-scale tunnel boring machine (TBM) is currently the most advanced equipment for underground tunnel excavation. The main bearing, carrying all the load and moment from the cutterhead, is hailed as the heart of TBMs, which connects the cutterhead and main drive system. Due to the harsh underground working conditions, the main bearing is prone to fatigue failures, which decreases its service life and could lead to extremely high replacement cost. To enhance the service life, different types of main bearings are used in TBMs depending on the geological structures. To develop a reasonable asset management and maintenance solution, it is crucial to understand the types of fatigue failures of the main bearings. This paper reviews the types and causes of fatigue failures in TBM main bearings based on practical experiences during the inspection and maintenance of over 100 sets of TBM main bearings made by different manufacturers. Fatigue failures in the TBM main bearings, including fatigue wear of components, etching cracks, peelings, rustiness, crushing damages, and bolt fractures, are mainly caused by overload, poor lubrication, foreign objects entering the main bearing interior, and non-standard operation and maintenance. The properties of different structural designs and their effects on the fatigue life of the main bearings are also presented. Furthermore, the selection of main bearings under different working conditions is discussed in order to reduce the occurrence of bearing failures. Finally, future research directions for TBM main bearings are elaborated.

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http://hdl.handle.net/10453/184902