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Created on 08.27
TBM Cutter Bearing Failure Analysis
TBM cutter bearing failure is a common issue encountered during TBM tunneling operations. This study analyzes such failures, identifies the root causes of tool bearing damage, and proposes technical measures to prevent such failures, thereby laying a solid foundation for structural improvement and design optimization.
1
bearing overloading
Bearing overload prevents normal rotation, leading to uneven wear of the cutting tool. Excessive bearing preload can also result in excessive starting torque for the cutter, causing it to rotate intermittently and thereby inducing uneven wear on the cutter ring.
Reamer wear
It is highly hazardous when tool wear occurs during tunneling operations without being detected in time; such cases should be identified and addressed as early as possible. Damage can also result from excessively small internal bearing clearances, inappropriate or insufficient lubricants, excessive loads, severe corrosion, or improper bearing installation. All these factors can lead to fish-scale-like surface damage on the raceway and roller surfaces due to rolling fatigue, giving rise to delamination. To prevent overload-induced delamination, it is essential to select an appropriate internal bearing clearance, re-evaluate the lubrication method and lubricant, and ensure proper bearing installation.
2
bearing running hot
A malfunctioning cutter head cooling system can cause the bearings to overheat and seize; subsequent excessive wear leading to failure can subject adjacent cutting tools to overload and failure, thereby triggering rapid propagation of the failure until all cutting tools on the entire cutter head fail.
3
Bearing pitting corrosion
Pitting corrosion is a type of damage caused by rolling fatigue in materials, characterized by the formation of small point-like pits on the rolling surface. The causes of pitting corrosion include improper installation, shaft warping, or poor machining accuracy of the shaft or housing. To prevent pitting corrosion, proper shaft centering should be performed, and the machining quality of the shaft or housing should be improved.
Wear between the raceway and the ball
4
Bearing creep
The phenomenon where the bearing mating surfaces exhibit wear, discoloration, or scoring caused by sliding motion, or where the bearing ring undergoes circumferential displacement relative to the shaft or housing during operation – is known as bearing creep. The primary causes of creep are insufficient interference fit or inadequate tightening of the bearing ring. To prevent bearing creep, the interference fit should be increased and the bearing ring should be tightened appropriately.
5
Bearing fracture
The phenomenon where a fracture occurs in the outer ring, inner ring, or rolling elements, leading to the propagation of cracks in the component and the formation of two or more separate fragments. The causes of such fractures include: excessive interference fit, excessive fillet radius on the shaft or housing, excessive impact load, or the development of delamination or burn damage; or excessive impact load or the progression of delamination. To prevent such fractures, appropriate fitting should be selected, the fillet radius of the shaft or housing should be smaller than the bearing chamfer dimension, and the load conditions should be reconfigured.
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