Steel (0.06%C) billets are hot rolled into bars of 2 meters each. These rolled bars are then cut into specific lengths of ~2000mm and deep (blind) holes are drilled axially into these rolled bars (180mmx240mmx2000mm). Figure 1 shows the dimensions of the machined bar.
The tolerances of ±0.05mm needs to be maintained on the boring process. These deep holes (of Dia 30-50mm) are drilled to the length of 1700mm (overall length 2000mm) using a special purpose deep hole drilling machine.
It takes about 45 mins to complete the drilling process and additional 20 minutes to insert different (Circular bar) bar into the hole already drilled. The process is time-consuming, requires skilled labor.
Thus, we are currently looking for alternate and novel methods to get this manufactured and assembled with or without deep-hole drilling.