Mechanical rock-breaking tools generally perform poorly in cutting. To meet the “double carbon” target, it is important to reduce the consumption of metal materials and the waste of metallurgical energy. These issues are often caused by the frequent failures of rock-breaking tools in extreme geological formations. Such formations are characterized by high ground stress, high rock strength, and high quartz content. To address this, research has been conducted to support efficient rock breaking by full-face tunnel boring machines (TBMs) using disc cutters. This research includes establishing a laser theoretical model, designing a prototype laser cutting head, proposing a laser-assisted rock-breaking mode, and validating its feasibility. Initially, the introduction of a perforated spherical concave lens was proposed without altering the basic components of traditional laser cutting systems. This lens was aimed to improve the beam shaping principle of straight round lasers, thus suggesting a new adjustable power density distributed laser theoretical model. Subsequently, the structure of the prototype distributed laser cutting head was designed, and an integration scheme with the existing TBM cutterhead cutting system was provided. Based on the disc cutter rock-breaking mechanism, a laser pre-cutting groove-assisted adjacent disc cutters rock-breaking mode was proposed. Later, to analyze the rock-breaking effects of distributed lasers, on one hand, an improved plan for the laser cutting head optical assembly was proposed and simulated for verification; on the other hand, a laser rock-breaking experimental platform was further set up, and the rock-breaking effects of straight round/distributed lasers were compared and analyzed to determine the optimal object distance for subsequent experiments. Finally, experiments on disc cutter penetration into rock samples irradiated by straight round/distributed lasers under different distances from the cutter to the groove (DCG) were conducted. By comparing and analyzing the macroscopic rock fragmentation phenomena and the energy consumption of disc cutter penetration into rock, the feasibility of the new rock-breaking mode was preliminarily verified. The research results show that distributed lasers can fundamentally suppress the formation of vitreous glaze by reducing the laser power density in the outer non-core areas. By converting traditional straight round lasers into distributed lasers, the energy consumption during the penetration of tools into rock can be significantly reduced Additionally, the optimal DCG is increased. Compared to the traditional disc cutter rock-breaking mode, the proposed rock-breaking mode offers advantages such as better rock-breaking effects, lower energy consumption, and fewer required laser cutting heads and disc cutters.

中文翻译：

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用于 TBM 应用的可调功率激光切割头的可行性研究：关注岩石碎裂效率和能耗


机械破石工具通常在切割时表现不佳。为了实现“双碳”目标，减少金属材料的消耗和冶金能源的浪费非常重要。这些问题通常是由于极端地质构造中破岩工具的频繁故障引起的。这种地层的特点是高地应力、高岩石强度和高石英含量。为了解决这个问题，已经进行了研究，以支持使用滚刀的全断面隧道掘进机 （TBM） 实现高效破岩。本研究包括建立激光理论模型、设计原型激光切割头、提出激光辅助破岩模式并验证其可行性。最初，在不改变传统激光切割系统的基本组件的情况下，提出了穿孔球面凹透镜的引入。该透镜旨在改进直圆激光器的光束整形原理，从而提出一种新的可调功率密度分布式激光理论模型。随后，设计了原型分布式激光切割头的结构，并提供了与现有 TBM 刀盘切割系统的集成方案。基于滚刀破岩机构，提出了一种激光预切槽辅助相邻滚刀破岩模式。 后来，为了分析分布式激光器的破岩效果，一方面提出了一种改进的激光切割头光学组件方案并进行了仿真验证;另一方面，进一步搭建了激光破岩实验平台，对比分析了直圆/分布式激光器的破岩效果，确定了后续实验的最佳物距。最后，在从刀具到凹槽 （DCG） 的不同距离下，对圆盘刀/分布式激光照射下钻入岩样进行了实验。通过对比分析宏观岩石碎裂现象和滚刀钻入岩石的能耗，初步验证了新破岩模式的可行性。研究结果表明，分布式激光器可以通过降低外部非芯区的激光功率密度，从根本上抑制玻璃釉的形成。通过将传统的直圆形激光器转换为分布式激光器，可以显著降低工具穿透岩石过程中的能耗，此外，还提高了最佳 DCG。与传统的圆盘切割机破岩模式相比，提出的破石模式具有破石效果更好、能耗更低、所需激光切割头和圆盘切割机更少等优点。