Chip congestion is a long time bottleneck in deep hole drilling. This paper addresses the problem of chip state monitoring in single-edge deep hole drilling by computer simulation and experimental analysis. Two phenomenological models were proposed to interpret the physics of chip discharging in normal and congested states, respectively. Length and diameter of the chip are chosen to represent the geometric features of the chip, and the formation of a chip signal is discussed. Based on the two models different types of chips are used to simulate the monitoring process. Computer simulation shows that the normal chip discharging in a real drilling process can be interpreted by the proposed slug flow model. Also, the experiments with cylindrical form chips confirms model II proposed for a congested chip state in which the diametral effect develops due to chip congestion. The experimental analyses also find out the dependence of pressure signals on the various parameters of chips as well as the cutting process.

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