Upgrading effector design for heading machine used for tunneling in complex rocks during construction of St. Petersburg metro

DOI: https://doi.org/10.30686/1609-9192-2026-4S-165-171

Читать на русскоя языкеD.A. Yungmeister1, M.I. Timofeev1, R.I. Korolev2
1  Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation
2  ProTech Engineering LLC, Saint Petersburg, Russian Federation
Russian Mining Industry №4S/ 2026 p. 165-171

Abstract: The authors propose an upgraded effector for heading machines designed for the specific mining and geological conditions of St. Petersburg as a solution to the problem of reducing emergency failures of tunneling equipment. The article discusses options for fitting the effectors of mechanized tunnel-boring complexes with vibroactive roller cutters and combined cutters (a cutting blade combined with a roller cutter) that automatically alternate between the functions depending on the properties of the rock being removed. The required characteristics of the vibroactive roller cutters and the design features of the combined cutters with a rock chipper have been determined. It has been proved that implementation of the proposed solutions will reduce the emergency downtime by 30% and eliminate the risks of tunnel workers operating in hazardous conditions of the tunnel face collapse. A theoretical justification of the system’s dynamic parameters was performed using differential simulation. The authors propose a mathematical model of the cutting assembly dynamics. A physical experiment was performed using a Zwick Roell Z100 testing machine to verify the parameters and define the limiting cutting forces. A dedicated laboratory prototype of the rock-cutting tool was designed and manufactured for the tests. Continuous strain gauge measurements of the forces acting on the cutter were recorded during the experiment. The obtained values were fitted to the Drucker–Prager elastic-plastic model for numerical simulation of the stress-strain state of the rock mass using the ANSYS software suite. According to preliminary estimates, use of the heading machines equipped with the proposed upgraded rock-cutting tools will increase the tunneling speed while reducing maintenance costs for the working equipment by at least 20%.

Keywords: tunnel boring machine, rock-cutting tools, vibroactive roller cutter, cutter, complex rocks, tunneling speed, emergency downtime

For citation: Yungmeister D.A., Timofeev M.I., Korolev R.I. Upgrading effector design for heading machine used for tunneling in complex rocks during construction of St. Petersburg metro. Russian Mining Industry. 2026;(4S):165–171. (In Russ.) https://doi.org/10.30686/1609-9192-2026-4S-165-171

Article info

Received: 30.05.2026

Revised: 29.07.2026

Accepted: 20.08.2026

Information about the authors

Dmitrii A. Yungmeister – Dr. Sci. (Eng.), Professor of the Department of Mechanical Engineering, Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation; https://orcid.org/0000-0001-7858-8340

Maksim I. Timofeev – Postgraduate Student of the Department of Mechanical Engineering, Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation; https://orcid.org/0000-0002-9441-4532; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Roman I. Korolev – Cand. Sci. (Eng.), Chief Specialist of the Mining and Mechanical Sector of the Mining Design Department of the St. Petersburg branch, ProTech Engineering LLC, Saint Petersburg, Russian Federation; https://orcid.org/0000-0001-5247-9453

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