To address the issues of insufficient performance and high cost associated with integral
casting and additive manufacturing methods for parts with small-entry elliptical gradient deep cavities, and the difficulties, low efficiency, and high cost of
metal removal methods, this invention proposes a
machining method for elliptical gradient deep cavities with small entry points. The method involves first rough drilling and rough turning to obtain a
deep hole. Then, a step-by-step
machining approach is adopted, dividing the part into regions and
machining them axially and radially. First, the part is tilted to
machine the regions on both sides of the major axis of the
ellipse. Then, the part is turned upright to
machine the regions on both sides of the
minor axis of the
ellipse. During the upright machining, a radial layering and thin-
cutting fast-running method is used. Several
layers are machined using the first toolpath until the machining residue in the
undercut and triangular regions is removed. Then, a second toolpath is used for contour machining to obtain a gradient deep cavity with an elliptical cross-section. Finally, the gradient deep cavity is precision milled until its internal dimensions and
surface roughness meet the design requirements.