Title: Tool and process development for chambering bores with non-circular contour in highly stressed workpieces

Authors: Julian Frederic Gerken; Robert Schmidt; Dirk Biermann; Moritz Fuß

Addresses: Institute of Machining Technology, TU Dortmund University, Baroper Str. 303, 44227, Dortmund, Germany ' Institute of Machining Technology, TU Dortmund University, Baroper Str. 303, 44227, Dortmund, Germany ' Institute of Machining Technology, TU Dortmund University, Baroper Str. 303, 44227, Dortmund, Germany ' BGTB GmbH, Dorstfelder Hellweg 60, 44149 Dortmund, Germany

Abstract: A novel chamber boring system allows for contouring of boreholes in axial and radial direction to produce special profiles required from oil industry. The machined contour, produced by this system, consists of six convexities in radial direction. In this paper, the development of the cutting tool and its kinematics are described. Due to the fully mechanical drive of the system, different tool designs cause a distortion of the resulting contour. In addition, the cutting parameters also affect the machined profile. The resulting contour deviations were analysed and measured by a 3D-coordinate-measuringsystem. To ensure transferability to industrial applications, a process strategy with re-cutting after a tool change was developed and analysed using an optical 3D measurement system. With this strategy and the improved tool kinematics, it is possible to machine a workpiece with a length of l = 2500 mm. Future research projects investigate the possibility to substitute the mechanical drive with an electrical drive.

Keywords: chamber boring system; deep hole drilling; strain gauge; torque measurement; tool development; process optimisation; internally profiled workpieces with small internal diameters; MUD drive production.

DOI: 10.1504/IJMMS.2021.121245

International Journal of Mechatronics and Manufacturing Systems, 2021 Vol.14 No.3/4, pp.289 - 304

Received: 30 Jul 2021
Accepted: 21 Sep 2021
Published online: 01 Mar 2022 *