Optimization of Internal Chip Evacuation Cutting Tool System for Deep Bottle Holes Based on Chip Morphology Control

Complex deep hole parts are crucial for major equipment to achieve structural innovation and technological leapfrogging. With the continuous advancement of requirements for weight reduction, efficiency enhancement, and performance modification, the application of deep bottle hole parts has become increasingly widespread. Their structures are mainly characterized by complex interior profiles, variable diameters, large depth-to-diameter ratios, etc. However, the traditional vibration-damping tool boring process is prone to problems such as poor hole straightness and low cutting efficiency due to poor tool rigidity and difficult chip evacuation. For this reason, this research focuses on an internal chip evacuation tool system for deep bottle holes based on cutting morphology control. First, based on the structural characteristics of deep bottle hole components, a specialized tooling system with three guide pad supports and internal chip evacuation channels was designed. Subsequently, the tool's chip evacuation channel was optimized using fluid simulation results from the tooling system, and the coupled relationship between chip morphology and chip evacuation efficiency was analyzed. Finally, a segmented and layered boring process scheme was proposed based on the component's structural features. Through deep bottle hole-boring experiments, the surface roughness of the hole interior reached 0.9 µm, and eccentricity was reduced by 54.39%, confirming that the scheme effectively forms chip morphology into spiral curled chips and validating the feasibility and effectiveness of the tooling system.