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

Area of Science:

• Mechanical Engineering
• Manufacturing Technology

Background:

• Deep bottle hole parts are vital for advanced equipment, demanding high precision.
• Traditional boring methods struggle with complex geometries, leading to poor hole quality and low efficiency.

Purpose of the Study:

• To develop an internal chip evacuation tool system for deep bottle holes.
• To enhance machining accuracy and efficiency for complex deep hole components.

Main Methods:

• Designed a specialized tooling system with guide pads and internal chip evacuation channels.
• Optimized the tool's chip evacuation channel using fluid simulation.
• Analyzed the relationship between chip morphology and evacuation efficiency.
• Proposed a segmented and layered boring process scheme.

Main Results:

• Achieved an internal surface roughness of 0.9 µm.
• Reduced eccentricity by 54.39%.
• Successfully formed chips into spiral curled shapes for efficient evacuation.

Conclusions:

• The developed tooling system and process scheme are feasible and effective for deep bottle hole machining.
• The internal chip evacuation system significantly improves hole straightness and cutting efficiency.