BIG KAISER High Performance Tooling Solutions 2018-2019

FINE BORING HEADS

FINISH BORING TROUBLESHOOTING Under certain conditions, it may be necessary to modify or adapt recommended cutting data and/or tooling configurations of the application. Below are general solutions to common problems.

Problem

Possible Cause

Remedy

Wrong insert grade

Change to higher wear resistant grade

Excessive speed

Reduce SFM

Poor Tool Life

Poor cooling of insert

Apply through-tool coolant

Excessive stock allowance

Decrease depth of cut

Excessive speed

Reduce SFM, check cutting data tables Shorten tool to increase stiffness Increase boring bar diameter to larger size Change boring bar to carbide or heavy metal Reduce nose radius of insert Use ground geometry inserts (ie: TAN18 grade)

Extreme length/diameter ratio

Chatter & Vibration

Wrong insert

Incorrect stock allowance

Check cutting data tables

Worn and/or damaged tool shank; replace Clean spindle and tool shank Semi-finish with twin insert boring head Use ground geometry inserts (ie: TAN18 grade) Change to auto-balance or balanceable head Balance tool assembly Reduce speed

Inaccurate tool changes

Poor Size Repeatability

Variation of stock allowance Excessive spindle looseness

Excessive boring tool imbalance

Unacceptable Roundness

Excessive cutting forces

Check stock allowance and feed rate Check for uniform workpiece clamping

Insufficient workpiece clamping

Reduce cutting forces; change to ground insert Increase cutting speed, reduce feed Semi-finish with twin insert boring head Decrease depth of cut Decrease insert radius Reduce cutting forces; change to ground insert

Workpiece non-symmetrical

Original bore off position

Unacceptable Position

Excessive stock allowance

Wrong insert radius Excessive feed rate

Use larger insert radius

Reduce feed; maximum 25% of insert radius Increase bore to boring bar clearances Apply through-tool coolant; adjust nozzles Change insert to higher rake angle Check depth of cut Change to higher wear resistance insert grade Increase insert radius Change from ground to pressed geometry insert Increase coolant flow

Poor Surface Finish

Poor chip evacuation

Taper

Premature insert wear

471

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