A Comprehensive Approach to Improving Accuracy, Tool Life, and Surface Quality in Hole Reaming

This paper aims to improve surface quality and hole accuracy during reaming. A modular cutter-type reamer with rigidly fixed, peackless cutting edges was used to ensure that the finishing reaming operation was highly efficient, increased machining accuracy and quality, and reduced the surface roughness of the machined parts. It was found that when the fourth cutting edge of the reamer engages, the radial component of the cutting forces balances out. Consequently, machining stability increases, tool deflection and vibrations decrease, and the accuracy and quality of hole machining improve. Design modeling of modular cutter-type reamers was performed using the APM WinMachine software package, which increased design productivity and enabled the analysis of multiple cutting conditions on simulated models. Calculations showed that a modular cutter-type reamer with rigid fixation of peackless cutting edges arranged along a helical line has smaller radial displacement than other reamer designs. Consequently, longitudinal and transverse deviations are reduced by 1.2 times, leading to higher accuracy and improved hole quality. Additionally, the load on each peackless cutting edge decreases by 1.5 times, and the tool's strength increases by 1.3 times. This results in an enhanced tool life and durability. Optimal cutting parameters for the modular cutter-type reamer with rigidly fixed peackless cutting edges were experimentally determined: a spindle speed of 160 rpm, a feed rate of 0.2 mm/rpm, and a machining allowance of 0.5 mm. The developed reamer demonstrated high hole machining accuracy within the range of 0.005-0.016 mm (IT5–IT6 tolerance grades), which is 1–2 grades higher than that achieved with boring tools or standard solid or modular reamers. Surface roughness values were obtained within the range of Ra = 0.125-0.8 μm.