Boring

Global Knowledge
g Center
 Outline

• Boring Bar Nomenclature

• Tooling
g Geometries Part 1

• Tooling Geometries Part 2

• Application Hints

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Boring Bar Nomenclature - ISO

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 Boring Bar ISO Nomenclature

C Top Clamp
M Top Clamp + Pin in Hole

S – Tool
T l Steel
St l P Lever Clamp
S Screw Clamp Insert Length
A – Tool Steel with int coolant
Method of With Insert Thickness
C – Carbide Tools with steel head T3 (3.97mm)
Bar Holding
g
E – ‘C’ + int coolant Insert Bar Hand of
Diameter
F – ‘C’ + Vib. Absorption shank Style/Cutting Bar
Edge Angle
H – Heavy
y metal shank

Material of
Boring bar: S 20 S S C L C R 09 / 09T3
Steel
A 32
C 50 Insert
H 100 Shape
Insert
M 150
Length of Clearance Insert
R 200 Length
Boring bar
S 250
T 300
V 400
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 Tooling Geometries Part 1

• Radial & Axial Rake Angles

g
• Deflection
• g Clearance
Boring
• Boring Bar Selection
– Workpiece
– Machine
– Boring Bar
• Effect of Chatter
• Largest Diameter – Shortest Length
• Boring Bar Design
• Coolant – Through or Not?

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Radial & Axial Rake Angles

Negative

Radial Radial
Positive

Negative
Axial Axial
Positive

Negative rake Positive rake

• Strong cutting edge • Freer cut
• High tool pressure • Lower tool pressure

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 Deflection must be minimized

Direction Direction
of bore of bore
rotation rotation

Original Position

Deflected Position
Original Position

Deflected Position

Bore Bore

• Deflection minimization is critical

– Measurement, chatter
• Bar may be off-set to minimize deflection impact
– Long L / D ratios
– Small
S ll di
diameter
t bboring
i (b(bar manufactured
f t d .01”
01” (0
(0,25
25 mm)) above
b center)
t )

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 Boring Clearance

Negative rake inserts can have clearance problems if the bar deflects.

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 Boring Bar Selection

Workpiece Machine Boring bar

• Depth of hole • Workpiece chucking • Length to diameter

method ratio
• Diameter of hole
• Coolant plumbing and • Composition
• D.O.C. Requirements application
• Special features • R
Rake
k & clearance
l
• Method of checking angles
(profiling, threading,
center height
grooving
g g etc.)) g
• Center height
• Boring bar holding
• Finish requirements
method • Lead angle/cutting
• Interruptions
p o ces
forces
• Chip clearance

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 Effect of Chatter

There are three factors that will counteract the chatter:

• The Static Stiffness of the bar.
• The Natural Frequency of the bar.
• The
Th Vibration
Vib ti Damping
D i Ability
Abilit off the
th cutting
tti system.
t

Results of Chatter
• Poor surface finish
• Tapered holes
• Loss of accuracy
• Limited production Steel shank DeVibrator with through
• Increased scrap coolant
M
Max. 6:1
6 1 overhang
h ratio
ti

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Largest Diameter

1” Dia. (25 mm) 1.25” Dia. (32 mm) 1.5” Dia. (40 mm) 2” Dia. (50 mm)
Basic Rigidity
g y 2 1/2 Times Increase 5 Times Increase 16 Times Increase
in Rigidity in Rigidity in Rigidity

Choose the largest possible diameter boring bar for maximum rigidity.

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 Length to Diameter Ratio

If you have a 1” (25 mm) diameter steel bar and it’s sticking out 4” (100
mm), ), it’s 4 to 1 ratio.

Length

Diameter

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 Shortest Length

L
Example: 1“
1 (25 mm) diameter steel bar

Overhangg L/D Stiffness

4” (100 mm) 4/1 basic stiffness
3” (76 mm) 3/1 2.4 x as stiff
2” (50 mm) 2/1 8 x as stiff
1” (25 mm) 1/1 64 x as stiff

Choose the smallest overhang for maximum rigidity.

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Boring Bar Design

• The larger diameter at the rear of • The smaller diameter

th bar
the b – Decreases
D weight
i ht att th
the ffrontt off the
th
– Increases stiffness where the bar
bending moment is the greatest. – Increases the natural frequency
– Allows the bar to enter the small
bore diameter.

Holder

Keep the bar as rigid as possible!

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Boring Bar Composition

Composition Length to Diameter ratio

Steel 4/1

Heavy Metal 4/1 to 6/1

Steel/DeVibrator 6/1

Tungsten Carbide 6/1

C bid /D Vib t
Carbide/DeVibrator 8/1

Standard Tuneable Boring Bar 6/1 to 10/1

Special Tuneable Boring Bar over 10/1

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 Tunable Tooling Solutions

Tunable Milling Adapter

Tunable Boring Bar

Tuning is the process of matching the systems natural frequency with operating
frequency using an adjustable damping mass system.
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 Coolant - Through or Not?

Coolant promotes:
• Chip disposal
• Tool life

A 1” (25 mm) diameter bar

with a .12” (3 mm) diameter
coolant hole suffers a 0.06%
change in rigidity

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 Tooling Geometries Part 2

• Effect of Minimum Lead Angle

• Lead Angle Selection Criterion

• Insert Nose Radius

• Chip Clearance

• Selecting a Machine

• Method of Holding

• Key Elements of Application

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 Effect of Minimum Lead Angle

• A lead angle is almost always

preferred in TURNING
• A 0°lead angle is almost always
preferred when BORING

Feed
– 15°lead
15 lead angle - tends to deflect Force
the boring bar and may 15° Lead Angle
contribute to chatter.

– 0°lead angle - directs the feed

force back through the axis of
the boring bar and minimizes
deflection and chatter.
Feed
Force
0° Lead Angle
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Lead Angle Selection Criterion

• Machine rigidity

• Set-up rigidity

• Workpiece configuration

• Availability of tool positions in turret

• Economics - one tool for several operations

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 Insert Nose Radius

• Large nose radius

– Better surface finish

– Higher
Hi h ttooll pressure

– Risk for chatter and deflection R .015” (0,4 mm)

Force
• Small nose radius
– Lower tool pressure Force

Force directed
i
into toolholder
lh ld
R .015” (0,4 mm)

R .005” (0,13 mm)

Force pushes tool

away from part
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 Chip Clearance for Blind Holes

The Chip Clearance Should Be Twice the Depth of Cut

(Width of the Chip)

Example:
Depth of Cut is .12
12” (3 mm)
2 x .12” (3 mm) = .24” (6 mm)
Chip Clearance

Adequate chip clearance

is necessary for chip
evacuation.
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Chip Clearance

LESS

MORE To gain more chip clearance on the insert side of the

bar, use a bar with a larger distance from the
centerline to the cutting point - a larger “F”
dimension.

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Prevent Chip Packing in Blind Holes

Feed

• Two notes of caution:

– Verify clearance under the back side of the insert
– Watch for insert movement in the pocket

One way to promote chip evacuation, especially in blind holes, is to advance to

the bottom of the hole and bore on the way back out. This helps to pull the
p out of the bottom of the bore.
chips

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Machine

What do we need to consider when selecting a

machine for a boring operation?

• Workpiece Chucking Method

• Coolant Plumbing and Application

• Method of Checking Center Height

• Boring Bar Holding Method

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Method of Holding

Sleeve, Split Bushing or Collet

2-point
p contact Multi-point
Multi point contact

Use a clamping method that maximizes the number of point of surface

contact on the periphery of the bar!

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Holding Systems

Good

Better

Best

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Key Elements of Application

• Tool Maintenance

• Overhang

• Centerline

• Tool Holding Method

• Application Hints

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 Application Hints

• Inspect
p the Pocket
• Inspect the Clamping
• p / Screw Inspection
Lockpin p
• Chip Control Options
• To Reduce Tool Pressure
• Application Hints
– Interruptions
– Soft & Gummy Material
– Work Hardening Materials

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Chip Control Options

Machine Insert & Holder

• FEED RATE • LEAD ANGLE
– Usually Increase – Change to redirect
• SPEED • GEOMETRY
– Increase – Tighter
g ((closer to tip)
p) or
• DEPTH OF CUT Positive
• NOSE RADIUS
– Usuallyy Increase
– Smaller
• COOLANT
• EDGE PREP
– Through
g the Bar, More
Pressure or Redirect – Sharp, hone, or T-land

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To Reduce Tool Pressure:

• Positive
os t e Rake
a e Tool
oo Geo
Geometry
et y

• Minimum Lead Angle

• Smallest Possible Nose Radius

• Reduce the Depth of Cut

• Reduce Feed

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Application Hints

Interruptions
p
• Increase Speed
• Increase Lead Angle
• Larger Nose Radius
• Reduce Feed
• Thicker Insert
• Stronger Geometry (Round, Square etc.)
• Consider Edge Prep (Hone or T-Land)

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Application Hints

Soft & Gummy Materials

• Sharp Edge
• Positive or High Positive
• Polished Top Rake Face
• Higher Speed
• PVD Coated (Steel)
• High Pressure Coolant (Chip Control, Tool Life)
• R di t Chi
Redirect Chip F
From W
Workpiece
k i (Chi
(Chip M
Management)
t)

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Application Hints

Work Hardening Materials

• Sharp Edge for finishing
• Positive Rake (for Non-Interrupted)
• Do not Dwell in the Cut
• Moderate Speed/Higher Feed
• PVD Coated for finishing
• Increase Lead Angle
• Maintain Sufficient feed rate of .003 IPR (0,8 mm) minimum.
• Check insert for build-up before index

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Inspect the Pocket

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Inspect the Clamping

Do not
over
tight
g

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Questions ??

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