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<p>In deep hole machining, traditional boring bars with a length-to-diameter (<i>L</i>/<i>D</i>) ratio exceeding 6 often face severe vibration challenges due to insufficient dynamic stiffness and damping capacity. This study presents a novel CFRP boring bar with a CLD structure, designed through a comprehensive framework integrating finite element analysis (FEA), modal experiments, and cutting tests. Key parameters, including fiber orientation and damping-to-constraining layer thickness ratios, were systematically analyzed to optimize natural frequency, dynamic stiffness, and damping characteristics. The optimized CFRP boring bar, fabricated via filament winding, exhibited a 35.4% increase in natural frequency and a 40% reduction in vibration amplitude compared to tungsten carbide bars. Cutting tests demonstrated stable machining at <i>L</i>/<i>D</i> = 8.78, with chatter-free surfaces even at 0.25 mm depth of cut. This study provides a theoretical foundation for CFRP tool design and validates its practical potential in aerospace manufacturing, such as high-precision boring of turbine engine casings.</p>

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Design and chatter suppression of a CLD-structured CFRP boring bar for high-precision deep hole machining

  • 期刊论文

  • 发表日期：

    2025年6月23日

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  • Gang Liu,
  • Licheng Lu,
  • Wenlu Su,
  • Junli Li,
  • Qinglong An,
  • Liqiang Zhang,
  • Jian Mao

摘要

In deep hole machining, traditional boring bars with a length-to-diameter (L/D) ratio exceeding 6 often face severe vibration challenges due to insufficient dynamic stiffness and damping capacity. This study presents a novel CFRP boring bar with a CLD structure, designed through a comprehensive framework integrating finite element analysis (FEA), modal experiments, and cutting tests. Key parameters, including fiber orientation and damping-to-constraining layer thickness ratios, were systematically analyzed to optimize natural frequency, dynamic stiffness, and damping characteristics. The optimized CFRP boring bar, fabricated via filament winding, exhibited a 35.4% increase in natural frequency and a 40% reduction in vibration amplitude compared to tungsten carbide bars. Cutting tests demonstrated stable machining at L/D = 8.78, with chatter-free surfaces even at 0.25 mm depth of cut. This study provides a theoretical foundation for CFRP tool design and validates its practical potential in aerospace manufacturing, such as high-precision boring of turbine engine casings.