JOURNAL OF ROCK MECHANICS

JOURNAL OF ROCK MECHANICS

Development of an Empirical Model for TBM Disc Cutter Wear Prediction Based on Operational and Geomechanical Parameters: A Case Study of the Qomroud Water Conveyance Tunnel

Articles in Press

Document Type : Original Article

Authors
Milad Sabbaghi 1
Ebrahim Farrokh 2
1 Mining engineering department,-Amirkabir university of technology
2 Faculty of Mining Engineering, Amirkabir University of Technology (Tehran Polytechnic)
10.22034/irsrm.2026.580580.1079
Abstract
Disc cutter wear in hard rock TBMs is inherently a multi-parameter phenomenon; however, conventional prediction models have predominantly reduced it to rock abrasivity indices. In this study, based on field data obtained from 18 km of excavation in the Ghomroud Water Conveyance Tunnel, an empirical framework was developed that quantitatively integrates operational parameters—including normal force, rolling force, cutterhead rotation speed, penetration rate, and cutter radial position—simultaneously with geomechanical indices such as UCS and RMR in predicting cutter wear rate. The modeling structure was independently formulated for center–face and gauge cutter zones to explicitly capture differences in stress distribution and loading mechanisms across the cutterhead. The resulting multivariate models achieved coefficients of determination of approximately 0.88, demonstrating high predictive capability. Validation through large-scale FDAT tests under varying loading and rotational conditions indicated less than 20% deviation between predicted and measured wear values. Comparative assessment against conventional rock-index-based models revealed a statistically meaningful improvement in prediction accuracy and a more realistic estimation of wear progression. The proposed framework provides a reliable basis for operational parameter optimization and cutterhead intervention planning in hard rock TBM projects.
Keywords
Abrasivity
Disc cutter
Operating parameters
Tunnel boring machine (TBM)
Subjects
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JOURNAL OF ROCK MECHANICS

Articles in Press, Accepted Manuscript
Available Online from 18 June 2026