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Designing a solid shaft that transmits power from a motor to a machine tool involves a series of calculations to ensure the shaft can withstand the stresses applied by bending moments and torques. First, calculate the torque exerted on the gear, considering the power transmitted by the shaft and its rotational speed. Following this, compute the tangential forces acting on the gears, which directly relate to the torque and the gear radius.
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Operating Properties of Deep Hole Boring Tools with Modified Design.

Norbert Kępczak1, Grzegorz Bechciński1, Radosław Rosik1

  • 1Institute of Machine Tools and Production Engineering, Faculty of Mechanical Engineering, Lodz University of Technology, Stefanowskiego 1/15, 90-537 Lodz, Poland.

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Summary

This study revised deep hole boring tool designs, finding polymer concrete shanks reduced displacement by 14.59%. However, despite promising initial results, the modified boring bar design is not recommended for operational use.

Keywords:
boring bardynamic propertiesfinite element methodmodal analysisstatic properties

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Area of Science:

  • Mechanical Engineering
  • Materials Science

Background:

  • Deep hole boring tools are critical in precision manufacturing.
  • Optimizing tool design can enhance performance and reduce vibrations.
  • Previous designs may have limitations in stability and material damping.

Purpose of the Study:

  • To investigate a revised design for a deep hole boring tool.
  • To evaluate the impact of structural modifications, specifically to the shank, on tool performance.
  • To assess the viability of using polymer concrete and rubber-doped polymer concrete in tool shanks.

Main Methods:

  • Theoretical analysis using 3D modeling and Finite Element Method (FEM) for strength testing.
  • Experimental modal analysis and static analysis to compare dynamic and static properties of original and prototype tools.
  • Operational boring tests on various workpiece materials to evaluate surface geometric structure (SGS) parameters like roughness (Ra, Rz).

Main Results:

  • Theoretical analysis showed reduced displacement for modified shanks: 14.59% for polymer concrete and 4.84% for rubber-doped polymer concrete (SBR-styrene butadiene rubber).
  • Experimental tests compared dynamic and static properties of the original and prototype boring bars.
  • Operational tests assessed surface geometric structure (SGS) parameters, including roughness (Ra, Rz), during boring.

Conclusions:

  • Modified deep hole boring tool designs with polymer concrete or SBR-styrene butadiene rubber-doped polymer concrete shanks demonstrated reduced displacement in theoretical and experimental stages.
  • Despite initial positive findings in theoretical and experimental analyses, the operational study indicated that the revised boring bar design is not recommended for practical application.