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Twin Insert Disc Cutter

Carbide-studded disc cutters are disc cutters in which several tungsten carbide inserts (buttons) are embedded on the cutter ring to replace the continuous solid cutting edge. They are categorized into studded single-edged roller cutters, studded central double cutters, and studded gauge cutters. As impact-resistant cutters, they serve as an upgraded version of smooth cutter rings. I. Structural Features The cutter ring matrix is made of alloy steel. The tungsten carbide inserts are fixed in the tooth holes via interference press-fitting or shrink-fitting. Common shapes of carbide inserts include spherical, wedge, conical, and bullet-head teeth. The internal bearings, oil seals, and spindle structures are fully interchangeable with those of standard smooth single-edged roller cutters, allowing for direct replacement of the entire cutter assembly. II. Applicable Geological Formations Fractured surrounding rock, rock formations with well-developed joints, and rocks with numerous fissures. Weathered rock, gravel layers, alternating hard and soft strata, and fault zones. Formations that generate severe vibrations and high impact loads during excavation, which easily cause chipping of solid cutting edges. III. Advantages (1) Strong impact resistance, significantly reducing the risk of overall cutter ring cracking or cutting edge spalling. (2) Concentrated point loading makes it easier to wedge into fissured rock, resulting in superior rock fragmentation and loosening effects. (3) Worn carbide inserts can be replaced individually, leading to lower maintenance costs. (4) Offers a more stable service life than smooth cutters under jamming and bouncing conditions.

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Disc Cutter

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Disc Cutter

Our Comprehensive Support Program

Every meter counts. We ensure you dig further.

When a cutter fails underground, it’s not just a tool that stops—it’s your entire project schedule. Every unplanned cutter change eats into your time. Every hour of downtime is a real hit to your bottom line. The cutters we build are designed to stay in the ground, not be pulled out.

"The true cost of a cutter has never been its purchase price; it’s how many downtime events it can prevent."

1. How Our Disc Cutters Lower Your Project Costs

Whether you're driving long-distance, large-diameter metro tunnels or running a series of short, small-diameter pipe jacking operations, choosing the right disc cutter is one of the most critical investment decisions you'll make in the long run. The actual project costs tied to disc cutters are extensive:

A. Advance Rate (TBM / Pipe Jacking penetration efficiency)

B. Cutter Ring Wear (Durability of H13 / DC53)

C. Bearing Consumption (Reliability of Timken® bearings)

D. Downtime for Cutter Changes

E. Inventory & Rebuild Costs

2. Advance Rate

Choosing a cutter ring with the optimal edge width makes a massive difference in your advance rate. We use premium, modified H13 or DC53 alloy steel rings, vacuum heat-treated (quenched and tempered) to achieve peak material performance, ensuring they stay sharp even in the most abrasive ground conditions. We have the expertise to help you select the most efficient cutting tools for your mining, water conservancy, or urban rail transit projects.

3. Bearing Consumption

Our disc cutters feature US-made Timken® bearings, which consistently outperform other brands under dynamic loads and harsh environments. Even in the toughest operating conditions—from urban utility tunnels to complex mixed-face ground—our bearing assemblies effectively handle extreme thrust loads and prevent premature failure.

4. Lost Boring Time

Time spent changing cutters is time lost boring. Our optimized seal and mounting designs allow for faster inspections and quicker replacements. This directly translates to more boring hours and helps you finish your project ahead of schedule.

5. Rebuild & Inventory Costs

The streamlined part count of our disc cutter assemblies means you need less on-site inventory. By using top-tier H13/DC53 components, wear on every single part is minimized, reducing your on-site stock requirements and making your rebuild planning much more efficient.

6. Disc Cutter Selection

From 6-inch compact pipe jacking cutters to 20-inch heavy-duty TBM disc cutters—we cover every size, every ground condition, and every machine type. Our philosophy is simple: deliver maximum performance on your own equipment. We also custom-manufacture cutters for machines from any manufacturer (shield machines, TBMs, or pipe jackers), backed by the same uncompromising quality.

Whether your project is in urban rail transit, utility tunnels, or mining, our goal remains the same: to deliver the longest cutter life and the lowest cost per cubic meter of rock excavated. No matter the geology, no matter the machine—if you're looking to reduce the total cost of ownership for your disc cutters, we have the solution for you.