BIG DAISHOWA High Performance Tooling Solutions Vol 3

ROUGH BORING HEADS

ROUGH BORING GUIDELINES

Insert Selection & Stock Allowance BIG KAISER indexable inserts outlined in the Insert Selection & Cutting Data tables have been selected to give optimum results. Grades and geometry do not have to be specified at time of order. Insert radius is based on 2 major factors: 1. Length/Diameter ratio of tool 2. Depth of cut or material allowance • Select the largest nose radius available for cutting edge strength & higher feeds • Use small nose radius for light depth of cut & extreme L/D ratio Feed 1. Feed: Based on effective number of inserts, depending on roughing method • Balanced Cutting: 2 effective inserts • Stepped Cutting: 1 effective insert • Full Profile Cutting: 1 effective insert 2. Under normal rough boring operations, the effective feed rate is about 50% of nose radius

Insert Radius .008 (0) .016 (1) .031 (2) .047 (3)

Minimum D.O.C.

Maximum D.O.C.

L/D Ratio

.010 .020 .040 .060

.060 .120 .200 .325

>6:1 ≤5:1 ≤4:1 ≤4:1

• D.O.C. is stock allowance/side (radius)

Feed/IPR

Nose Radius .008 (0) .016 (1) .031 (2) .047 (3)

Balanced Cutting

Stepped Cutting

.008-.012 .014-.016 .020-.026 .020-.030

.004-.006 .006-.008 .012-.016 .012-.020

Power Consumption The power curve of the machine should be consulted and cutting data values adjusted accordingly. • HP Requirements = MRR x K • MRR = d x SFM x IPR x 12 • MRR = metal removal rate, cubic inches

Material

K Factor*

Steel

.750

Alloy Steel Cast Iron Aluminum

1.000

.650 .430

• d = radial depth of cut, inches • SFM = surface feet/minute • IPR = inches/rev

High Temp Alloys

2.000

*With positive cutting geometry only

General Rule: Boring bar (ØD 2 ) should always be smaller than original hole size (ØD 1 ).

L 2

It is very important to allow for clearance between boring bar and rough bore diameter. ! CAUTION

L 1

444

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