Design of a boring bar with integrated lightweight construction and sensor technology for stabilizing internal turning processes

Titelangaben

Schmidt, Julian ; Roppelt, Dominik ; Thorenz, Benjamin:
Design of a boring bar with integrated lightweight construction and sensor technology for stabilizing internal turning processes.
In: Procedia CIRP. Bd. 142 (2026) . - S. 654-659.
ISSN 2212-8271
DOI: https://doi.org/10.1016/j.procir.2026.05.324

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Abstract

Machining processes are used in almost every manufacturing company. In many production systems, particularly in the machine building and automotive industries, they even represent the largest proportion of manufacturing processes and therefore have a significant influence on economic and environmental targets. Boring bars, typically used in internal turning processes, are characterized by a high length-to-diameter ratio, which makes them particularly vulnerable to vibrations. While the material removal rate (MRR) must be increased in order to improve productivity in cutting operations, the achievable maximum is usually limited by induced vibrations caused by dynamic load peaks in high force applications. This paper describes the design and testing of a boring bar with integrated lightweight construction and sensor technology to stabilize internal turning processes and thereby increase manufacturing quality and tool life. For this purpose, a sensor-integrated lightweight core made of carbon fiber-reinforced plastic was integrated into the boring bar. The orientation of the fibers was designed with the aid of simulation so that forces generated during the cutting process are absorbed as effectively as possible. Furthermore, the design of the tool body was adapted with a focus on the indexable insert seat so that a temperature sensor can be placed directly below the indexable insert. The subsequent experimental testing was carried out for an internal turning process, in which the process forces, wear and cutting edge temperature were examined and compared. It was shown that the mechanical properties of the lightweight core enabled the target variables under consideration to be optimized. The use of the generated sensor data for situation-dependent adjustment of the process parameters provides the basis for further optimizations.