Feng Yazhou, Xu Zixiang, Li Wanzhong, Shi Kaining, Zhang Yang, Yang Weiye
Mechanical Engineering College, Xi'an Shiyou University, Xi'an 710065, China.
School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, China.
Materials (Basel). 2025 Sep 11;18(18):4263. doi: 10.3390/ma18184263.
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.
复杂深孔零件对于大型装备实现结构创新和技术跨越至关重要。随着对减重、增效及性能改进要求的不断提高，深瓶形孔零件的应用越来越广泛。其结构主要特点是内部轮廓复杂、直径可变、深径比大等。然而，传统的减振刀具镗削工艺由于刀具刚性差、排屑困难，容易出现孔直线度差和切削效率低等问题。为此，本研究聚焦于基于切削形态控制的深瓶形孔内排屑刀具系统。首先，根据深瓶形孔零件的结构特点，设计了一种具有三个导向垫支撑和内排屑通道的专用刀具系统。随后，利用刀具系统的流体模拟结果对刀具的排屑通道进行了优化，并分析了切屑形态与排屑效率之间的耦合关系。最后，根据零件的结构特征提出了一种分段分层镗削工艺方案。通过深瓶形孔镗削实验，孔内表面粗糙度达到0.9μm，偏心度降低了54.39%，证实了该方案能有效地将切屑形态加工成螺旋卷曲切屑，验证了刀具系统的可行性和有效性。
