Process and Machine Improvements and Process Condition Monitoring For a Deep-Hole Internal Milling Machine

  • Wessley Wilmot

Student thesis: Phd


The University of Manchester - Wessley Jack Wilmot - Doctor of Philosophy - Process and machine improvements and process condition monitoring for a deep-hole internal milling machine - December - 2016.Milling is a widely used cutting process, most commonly applied to machining external surfaces of workpieces. When machining operations are required within hard to reach areas of components, or deep within the bore of components, alternative methods of metal removal are generally employed. Typically when milling at extended reaches, difficulties may increase exponentially when trying to achieve distances several meters into a component. Essentially every topic of the milling process becomes difficult and more convoluted. Firstly to generate a stable cutting condition, and ultimately for an operator to be able to understand the cutting conditions, when all normal senses to interpret the machining stability are removed. The aim for the research is, to enable the operation of high slenderness ratio internal milling operations to become a viable technology, by detailing the measures required, to obtain a stable cutting condition. The process needs to be monitored for degradation of the tooling due to wear, and to prevent catastrophic machine damage from tool breakage or machine component failure. This research addresses the lack of knowledge available for milling with extended reaches, and the knowledge gained to overcome the real difficulties that exist for this process. Initial experiments are conducted on a prototype machine to gain experience of the internal machining operation and the many issues that it faced. Establishing requirements of the process via investigation of the tooling and necessary auxiliary equipment, it becomes possible to consider countermeasures to address the errors generated by torsional twisting of the milling arm. A system for applying a counter torque to reduce torsional deflection errors has been employed to successfully reduce the unavoidable issue over such long distances. For the process to become manageable for an industrial operator without a high level of specialist knowledge, the application of tool condition monitoring (TCM) and process condition monitoring (PCM) had to be applied. This addresses a void in available literature and research with respect to internal machining, and enables the process to become practical for an industrial environment. For this reason the research project will concentrate on the application of TCM and PCM onto the machining system.The completion of the research resulted in the process becoming satisfyingly stable, and with a resulting accuracy that satisfies the requirements of the component. Performance of the final system rivalled or achieved better results than had been experienced by the project sponsor.
Date of Award1 Aug 2017
Original languageEnglish
Awarding Institution
  • The University of Manchester
SupervisorRobert Heinemann (Supervisor) & John Atkinson (Supervisor)


  • servo
  • Hydraulic
  • material removal
  • process condition monitoring
  • cutter compensation
  • internal machining
  • deep hole
  • cutting tools
  • Milling
  • machining
  • stator
  • tool condition monitoring
  • TCM
  • CNC

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