ROUGH BORING HEADS
ROUGH 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
Feed rate too low
Increase feed rate
Excessive height variation of inserts Width of chip excessive (D.O.C.)
Preset tool to max. .0002" variation of both inserts
Poor Chip Control
Preset tool for stepped cutting method
Excessive stock allowance
Consult cutting data tables
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
Extreme length/diameter ratio
Chatter & Vibration
Insert radius too large Unstable workpiece
Reduce nose radius of insert
Improve fixture and clamping support
Lead angle on insert holders
Change to 90 degree insert holders (type CC) Change to tougher grade of carbide insert Use larger radius if available
Wrong insert
Inserts Chipping or Breaking
Severe interruption
Increase speed, decrease feed
Check for boring bar/bore diameter clearance Improve chip control,increase feed
Chips packing and re-cutting
Wrong insert
Change to higher wear resistant grade
Excessive cutting speed
Reduce speed
Poor Tool Life
Inserts chipping
Check stock allowance and feed rate Increase through tool coolant pressure Adjust coolant ports of head if available
Coolant pressure too low
Boring bar diameter too large Excessive stock allowance Inadequate space below bore
Reduce to smaller head and extended range holder
Re-set tool for stepped cutting Elevate workpiece from table more
Chips Not Evacuating
Poor chip control Excessive feed rate
See above problem
Reduce feed; minimum 25% of insert radius Reset tool for stepped cutting method RPM in area of low spindle torque; increase speed RPM in area of gear change; adjust RPM Change insert to higher rake angle Reduce depth of cut
Stock allowance excessive
Insufficient Machine Power
Low machine torque
Excessive feed rate CC type insert holders
Reduce feed rate
Use square insert holders with 6 degree lead
Excessive Exit Burr
Reduce depth of cut Reduce insert radius
Cutting forces too high
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