Based on a tunnel project across a fault, a refined three-dimensional numerical model of fault tunnel surrounding rock was established in this study. The grouting pressure, jacking force, grouting hardening and nonlinear behavior of materials in actual shield construction were considered in the models. Through a series of numerical models, the deformation mechanism, mechanical properties and damage evolution of shield tunnels crossing fault fracture zones with different widths, dip angles and included angle were analyzed. In numerical simulation, the control variable method was used to change the width, dip angle and included angle of the fault respectively to study the influence of a single variable. The results showed that the deformation and damage area of tunnel vault were positively correlated with the increase of fault width. With the increase of the fault width, the arch extrusion became more obvious. However, when the fault width increased to a certain limit, the lining arch would converge to the tunnel from the surrounding rock, and the stress in the arch would increase first and then decrease. With the increase of fault dip angle, the inward convergence of lining arch crown first increased and then decreased, and the initial damage location was related to the fault dip angle. The damage scope and extent of the tunnel decreased continuously with the increase of fault included angle. The circumferential stress concentration was obviously affected by the fault included angle. With the increase of fault tendency, the radar stress gradually changed from "X" to "cross-shaped". Therefore, the tunnel should cross the fault orthogonally as far as possible in the stage of tunnel location and pre-reinforcement measures should be taken in advance when crossing a wide fault to ensure the safety and stability of the tunnel.
