Optimization method of cutter layout based on multi-objective particle swarm optimization algorithm: cases study

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Abstract As the primary rock-breaking components of full-face tunnel boring machines (TBMs), the spatial arrangement of disc cutters on the cutterhead is widely recognized as a key factor influencing excavation efficiency and operational stability. This study addresses the complex nonlinear optimization problem associated with cutter layout design under multi-objective constraints. A systematic optimization framework is established in which cutter load characteristics are derived from the CSM (Colorado School of Mines) rock fracture mechanics model. Three objective functions are rigorously formulated: minimization of cutterhead overturning moment, reduction of radial force magnitude, and minimization of mass-center deviation within cutter clusters. Boundary conditions, including non-interference constraints and equidistant installation requirements, are mathematically defined to ensure engineering feasibility. A MOPSO (multi-objective particle swarm optimization) algorithm is developed for planar cutterhead configuration and subsequently extended to dual-conical W-shaped cutterheads through parametric analysis of cone-angle-induced mechanical effects. Computational results indicate that the proposed MOPSO framework exhibits strong convergence performance, achieving optimal solutions within 60 and 180 iterations for planar and W-shaped configurations, respectively. The optimization process can be clearly divided into three stages: rapid improvement, diminishing returns, and asymptotic convergence. Comparative analysis demonstrates substantial performance improvements over conventional randomized, radial, and helical cutter layouts. The optimized configurations achieve reductions of 74.83% and 92.10% in the comprehensive objective metric for planar and dual-conical cutterheads, respectively. The proposed methodology is systematically validated as a robust theoretical framework for cutterhead design, particularly in resolving force equilibrium and enhancing energy efficiency in full-face tunneling operations.

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