Abstract: In the process of precision boring,the deep hole structure parts of the bottle cavity,represented by the aerospace engine vortex shaft,are prone to chip removal difficulties and low processing efficiency. The formation of chips during boring was studied,and the influence of different process parameters on chip morphology and chip removal effect was mastered. Based on the Box-Behnken design test,the finite element analysis method was used to simulate the deep hole machining process of the bottle cavity,and the chip curl radius prediction model was established with the process parameters as the independent variables,and the reasonable process parameters were selected to optimize the chip removal. The accuracy of the chip curl radius prediction model was verified by actual machining test. The test results show that the similarity between the test value and the predicted value was more than 90 %,which proves the validity and accuracy of the chip curl radius prediction model.

Key words: deep hole machining in bottle cavity, Box-Behnken test, chip morphology, gullet-to-chip area ratio