carbide boring bar - dorian tool · carbide bar 6 x dia., solution tool!™ 8 - 14 x dia. boring...

Call: 979-282-2861 Fax: 888-508-7055 Visit:www.doriantool.com E-mail:[email protected] 1 800-627-0266 800-508-7055

Flat Bed Deep Hole Boring Set-up

4 x Bar Dia.

1 Work holding

Use the proper chuck and jaws to hold the work-piece, to assure that the part is held with maxi-mum rigidity and stability under cutting force.

2 Steady Rest Support

When boring a long part, it is necessary to have extra support from the steady rest to eliminate any deflection of the part under the cutting force that causes vi-bration and poor surface finish.

3 Boring Bar Holding

For best results, hold the bar 4 x Dia. & choose a split collar boring bar holder. The 360° lock-ing system offers the largest sur-face contact between the boring bar and the holder, maximizing bar rigidity and minimizing vibration.

4 Boring Bar Size

Choose a boring bar with the largest diameter to clear the bore, maximizing rigidity. Make sure to provide enough clearance between the bore and the bar for chip evacuation so damaging does not occur on the bore wall. Also choose the shortest over-hang to reduce vibration.

5 Insert

To avoid and reduce vibration of the bar, that causes chattering. Use the insert with the as small of an angle geometry possible, small nose radius, high positive rake an-gle and sharp cutting edge.

6 Cutting Parameter

Use the recommended cutting data and parameter specified from the insert manufacturer, and use the cutting formula to max-imize performance, quality, and tool life.For a Roughing operation with a large depth of cut and a high feed rate, low RPM is recommended.For a Finishing operation with a small depth of cut and a low feed rate, high RPM is recommended.Minimum depth of cut is 1/2 of the insert radius. Maximum feed rate is 1/2 of the insert radius.

To Achieve Optimum Results for Deep Hole Boring It is extremely important to follow steps 1-6.

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Inch: 1/4”, 5/16”, 3/8”, 1/2’’ and 5/8” Diameter.Metric: 6mm, 8mm,10mm,12mm and 16mm Diameter.Boring Ratio: 8 x Dia., 10 x Dia., 12 x Dia., 14 x Dia.

CNC Turning Center Deep Hole Boring Set-up

1

5-6

42

3

4 x Bar Dia.

3

1

4

2 5-6

Integral Carbide Boring BarInstructions Manual

2 Call: 979-282-2861 Fax: 888-508-7055 Visit:www.doriantool.com E-mail:[email protected] 800-627-0266 800-508-7055

Maximum Boring Bar PerformanceSteel Bar 4 x Dia. Boring Ratio 2 x Dia. Threading Ratio 2 x Dia. Grooving Ratio• General boring bar applications• Roughing to finishing• Stable for high material removal• For small bores

Carbide Bar 6 x Dia. Boring Ratio3 x Dia. Threading Ratio 3 x Dia. Grooving Ratio• Best for boring small holes • Rigid for close tolerance and furnace finish • Rigid for heavy material removal at high ap and fn

Steel Body Solution Tool!™8 x Dia., 10 x Dia., 12 x Dia. Boring Ratio4 x Dia. Threading Ratio4 x Dia. Grooving Ratio • For deep hole boring applications

Carbide Body Solution Tool!™tion Tunable Boring 8 x Dia., 10 x Dia., 12 x Dia., 14 x Dia. Boring Ratio5 x Dia. Threading Ratio5 x Dia. Grooving Ratio • For high performance deep hole boring applications

Deep Boring Guide Line.✓ The diameter size of the boring bar is limited from the size of the hole diameter to be bored.

✓ The boring bar should have the largest diameter pos-sible for maximum cutting rigidity, but small enough to clear the hole for chip evacuation.

✓ The Boring Bar has to be held with the maximum rigidity (4x Dia. of the Bar) and the shortest overhang possible to maximize cutting stability.

✓ The selection and use of the right insert grade, geom-etry, nose radius and rake angle will be critical for a good surface finish and close working tolerance.

✓ The cutting parameter is to be correct for the materi-al machined in accordance of the insert manufacturing cutting data.

✓ The bore, while machined has to be kept clear from chips to avoid insert breakage, boring bar vibration,and undamaged the workpiece surface.

4 x Dia. Boring Ratio 2 x Dia. Threading Ratio

4 x Dia. Holding Area

6 x Dia. Boring Ratio 3 x Dia. Threading Ratio


8,10 & 12 x Dia. Boring Ratio 4 x Dia. Threading Ratio


8,10,12 & 14 x Dia. Boring Ratio 5 x Dia. Threading Ratio


Boring Bar Cutting Ratio: The material of the boring bar determinates the cutting ratio of the boring depth.

Steel Bar; for Short Depth 4xDia. Carbide Bar; Medium Depth for 6xDia. Solution Tool!; Long Depth up to 14xDia.

Boring Bar Cutting Ratio: Maximum cutting length of the boring bar in relation to its own body diameter Ex.: 1” (25mm) Boring Bar with 10 x Dia. Ratio, Maximum cutting length is 10” (250mm).

Boring Bar Holding System: When boring bar is not held properly and rigidly in the boring bar holder, vibration will develop when cutting. A split Boring Bar Holder must to be used.When holding the boring bar, the boring bar holder must:1. Have a Precise and smooth bore 2. Use the most rigid holding system of the boring bar 3. Have a holding length of the boring bar at 4 x boring bar diameter.

100%Rigidity!

80%Rigidity!

STOP!Do not Use it

360º Locking Force


Set Screw LockSolid Boring Bar Holder

Locking Screw


Split Collar Boring Bar Holder

Locking Screw

Locking Screw

Split Bushing Solid Boring Bar HolderSplit

Bushing

VerticalLocking Force


BEST Split Collar Holding SystemBoring Bar Holding SystemLocks the boring bar at 360º on the diameter, assuring the most rigidity and precise boring bar positioning Without scarring or damag-ing the bar surface.

GOOD Split Bushing Holding SystemWith a solid boring bar holderThe split bushing embraces the boring bar at 360º on the diameter. The screw will squeezethe bushing around the boring bar Without scarring or damaging the bar surface with precise positioning.

DO NOT USE IT Set Screw Lock Holding SystemSolid boring bar holder without bushing

Never lock the screw over the boring bar. Locking a screw over the boring bar will create only one point of contact causing very poor rigidity. Additionally, the screw will damage the boring bar surface and make position-ing difficult.


Insert Center Line Set-UpDue to the cutting pressure placed on the insert during deep boring, the bar flexes downward.Place the insert cutting edge above the center line. 10% diameter of bar. To compensate bar deflection and to reduce vibration.Example: 1” inch bar 1% = .010 25 mm bar 1% = .25

Cutting Parameter: Use the recommended cutting data and parameter specified from the insert manufacturer, and use the cutting formula to maximize performance, quality, and tool life.

INSERT GEOMETRY80°35° 55° 60°

CDV T80°35° 55° 60°

CDV T80°35° 55° 60°

CDV T80°35° 55° 60°

CDV T

INSERT RADIUSUse a smaller radius tolimit vibration

.004 r. .008 r. 1/64 r. 1/32 r.

INSERT CUTTING RAKEUse a positive cutting rake to limit vibration.

High Positive Positive Neutral Negative

INSERT RELIEF ANGLE5°7°11°

BCP15°

D5°7°11°

BCP15°

D5°7°11°

BCP15°

D5°7°11°

BCP15°

D

INSERT EDGE PREP

Sharp Honed Chamfered Chamfered & Honed

EF ST EF STEF STEF STINSERT CUTTING EDGE ANGLEUse a cutting edge angle as close to 90º as possible.

45°

High RPM

Small ap

Low fn

Low RPM

Large ap

High fn

Use the correct insert grade, geometry and characteristics for the material to be machined and the operation to be executed.For a Finishing operation and small depth of cut, use a wear resistant grade insert with a positive rake angle, small nose radius, sharp cutting edge, large chip break, and clearance angle. If the insert is too hard, it will chip and break under the cutting pressure, and vibration will develop. Switch to a softer grade. For a Roughing operation and large depth of cut, use an impact resistant insert with a positive rake angle, medi-um to large nose radius, honed cutting edge, large chip break, and clearance angle. If the insert is too soft it will wear prematurely, and friction will develop losing tolerance and good surface fin-ish, switch to a harder grade. Minimum depth of cut is 1/2 of the insert radius. Maximum feed rate is 1/2 of the insert radius.Best insert application:"V" for profiling and finishing"D" for general application"T" For light roughing and finishing"C" For heavy roughing

FINISHING ROUGHING

For a Roughing operation with a large depth of cut and a high feed

rate, low RPM is recommended.

For a Finishing operation with a small depth of cut and a low feed

rate, high RPM is recommended.

Minimum depth of cut is 1/2 of the insert radius. Maximum feed rate

is 1/2 of the insert radius.When wrong cutting parameters are used for the specific material to be bored, and for the operation to be executed, the boring bar will not perform properly, generating poor surface finish and/or vibration.

Boring Bar Overhang: Do not over stand the boring bar limitation.Steel bar 4 x Dia., Carbide bar 6 x Dia.,Solution Tool!™ 8 - 14 x Dia.Boring Bar Deflection: The bar under the Cutting Pressure will deflect.Use and set the boring bar to the correct overhang that is built for.

Incorrect Insert: Vibration are caused when incorrect insert geometry edge prep. (honing), nose radius, rake angle, chip breaker (too small), and clearance angle is used .


HIGH PRECISION FINISHING1 Hard and Abrasive Resistant Insert2 Ground, Polished and Coated3 Sharp Cutting Edge4 High Positive Chip Breaker5 PVD Microplus® Plasma Coating6 Low Cutting Force7 High Cutting Speeds (Vc)8 High Surface Finish

Material ApplicationP10 Carbon Steel & Alloy Steel AnnealedM10 Stainless SteelK10 Cast IronN10 Aluminum S10 High Temp Super Alloys

Insert ISO Grade UPC CCGT-060202-NFU DNX10UT 80021CCGT-060204-NFU DNX10UT 80025CCGT-09T302-NFU DNX10UT 80029CCGT-09T304-NFU DNX10UT 80033CCGT-09T308-NFU DNX10UT 80037

DCGT-070202-NFU DNX10UT 80049DCGT-070204-NFU DNX10UT 80053

TCGT-110204-NFU DNX10UT 80090

VCGT-110302-NFU DNX10UT 80099VCGT-110304-NFU DNX10UT 80104

Turning Inserts for Integral Carbide Boring Bar

MEDIUM / ROUGHING1 Tough and Impact Resistant2 Ground Periphery3 High Positive Molded Chip Breaker4 CVD Coated5 Heavy Material Removal6 Low Cutting Force7 Medium Cutting Speed (Vc)8 Good Surface Finish

Material ApplicationP25 Carbon Steel & Alloy Steel, AnnealedM30 Stainless SteelK10 Cast Iron

Insert ISO Grade UPC CCGT-060204-UEXL DPC25UT 70676CCGT-060208-UEXL DPC25UT 70682CCGT-060204-UEXR DPC25UT 70679CCGT-060208-UEXR DPC25UT 70685CCGT-09T304-UEXL DPC25UT 70688CCGT-09T308-UEXL DPC25UT 70694CCGT-09T304-UEXR DPC25UT 70691CCGT-09T308-UEXR DPC25UT 70697

DCGT-070204-UEXL DPC25UT 70712DCGT-070204-UEXR DPC25UT 70715

TCGT-110204-UEXL DPC25UT 70732TCGT-110204-UEXR DPC25UT 70735

FINISHING1 Hard and Impace Resistant Insert2 Precision Ground and Coated3 Sharp Cutting Edge4 Positive Chip Breaker5 PVD Coated6 Low Cutting Force7 High Cutting Speeds (Vc)8 High Surface Finish

Material ApplicationP10 Carbon Steel & Alloy Steel, AnnealedM10 Stainless SteelK10 Cast IronS10 High Temp Super Alloys

Insert ISO Grade UPC CCGT-060201-UEU DUP15VT 79451CCGT-060202-UEU DUP25GT 79453CCGT-060204-UEU DUP15VT 79456CCGT-060204-UEU DUP25GT 79458CCGT-09T302-UEU DUP25GT 79463CCGT-09T304-UEU DUP15VT 79466CCGT-09T304-UEU DUP25GT 79468

DCGT-070201-UEU DUP15VT 79531DCGT-070202-UEU DUP25GT 79533DCGT-070204-UEU DUP15VT 79536DCGT-070204-UEU DUP25GT 79538

TCGT-110201-UEU DUP15VT 79586TCGT-110202-UEU DUP25GT 79593TCGT-110204-UEU DUP15VT 79596

Re-Tuning Knob KeyDampener Position Locking ScrewThe screw is released before re-tuning and locked after tuning is complete.

Note:The choice of the correct insert, cutting parame-ters, are critical for the performance of the Solution Tool!™. For Deep Boring, the use of a small cutting radius, sharp cutting edge and a positive rake angle is recommended.

Re-Turning The Solution Tool!™ The Solution Tool!™ is dynamically tuned, tested and certified to meet Dorian Tool Quality control standards and performance and ready to be used.

Optimizing PerformanceCan be-retuned on the machine to optimize the boring bar performance when:

• Extreme and exotic materials change from very soft to very hard.

• Changing the boring depth. Ex: a boring bar with a 12 x Dia. boring Ratio will be used for a shorter boring Ratio like 6 x Dia..

• Improving performance for specific machining operations such as finishing, roughing boring, threading, and grooving.

1 Unlock dampener position locking screw.2 Insert Re-Tuning Key.3 While machining, turn the Re-Tuning Key very slow.3-1 Clockwise for roughing operations at low SFM.

3-2 Counter-clockwise for finish operations at high SFM.3-3 Until the optimized boring performance is reached4 Re-lock dampener position locking screw.5 Remove Turning Key


Problem Cause Solution

Vibration Boring Bar over extendedIncorrect Cutting Ratio

- Do not overextend the Boring Bar above the described cutting ratio: Steel Boring Bar: 4 x Dia. Carbide Boring Bar: 6 x Dia. Solution Tool!™: 8 x Dia., 10 x Dia., 12 x Dia., 14 x Dia..

Chattering

Boring Bar not rigid for the cutting pressureInsert angle geometry too large

Insert Cutting Radius too large: Too large contact area of the insert with the cutting surface.

Insert Cutting Rake angle too small: The chips do not flow freely away from the cutting surface of the workpiece and the insert cutting edge.

Insert relief angle to small: Cutting pressure pushes the insert down and the bottom will touch the cutting wall, pushing the insert up and down from the center line.

Insert edge prep: The insert cutting edge has too large of honing surface, this will affect more in small depth of cut and low cutting feed.

- Use a larger Bar Diameter- Reduce the Insert Angle Geometry: 80° Geometry for roughing 60° Geometry for general application 55° Geometry for finishing application 35° Geometry for profiling application

Change the insert with a small cutting radius and or increase cutting feed and reduce the RPM

Change the insert with a larger cutting rake angle

Change the insert with a larger relief angle and or place the insert cutting edge above the center line

Change to a sharp cutting edge and or increase cutting feed

Poor Surface Finish

RPM too low: At a low RPM, the cutting edge of the insert moves very slow over the cutting surface, no friction, no heat and little cutting force is developed resulting a poor and dull surface finish.

RPM too high: At a high RPM, the cutting edge of the insert moves very fast over the cutting surface generating friction, head and premature wear of the insert cutting edge, resulting a shine and uneven surface finish.

Increase the RPM.

Decrease the RPM.

Not holding dimensions &

tolerances

Boring bar deflection: Under the cutting force, the boring bar will deflect radi-ally and axially, dimensions and tolerances are difficult to be held.

Too large depth of cut: With a large depth of cut, lot of cutting force is placed over the boring bar deflecting radially and axially, and the dimensions and tol-erances are difficult to held.

Insert wear: If the insert cutting edge is wearing prematurely, dimensions and tolerances are lost, the RPM is too high and or the insert grade is soft.

Insert cutting radius too large: In a small depth of cut, a large insert cutting radius will not have enough engagement depth into cutting surface, the insert will be tearing rather than cutting with a poor surface finish, dimensions and tolerances.

Use a larger diameter boring bar to the maximum rigidity and minimize deflectionCheck the deflection of the Boring Bar to calculate the finish size.

1) Reduce the depth of cut to control and maintain dimensions and tolerances.2) For roughing operation, by trial and error calculate the bar deflection to establish the relation of the finish dimension, boring bar deflection and the depth of cut.3) For finishing operation, reduce the depth of cut, use an insert with a small angle geometry, and or a small cutting radius and sharp cutting edge.

Decrease the RPM and or change to a harder insert grade.

Increase the depth of cut, minimum depth of cut, should be not less than 1/2 the size of the insert radius, i.c. .016” (.4mm) depth of cut .008” (.2mm).Increase the depth of cut, and or change to a small insert cutting radius.

Whistling Cutting Sound

Insert cutting edge dull: The insert is not cutting, is rubbing and creating friction.

Insert Cutting Radius too Large: Too much contact of cutting edge and work piece.

Too Small depth of Cut: Insert cutting edge not engaged to the work piece.

Too High RPM: Too much RPM, creates friction and noises.

Replace the insert with a harder grade.

Replace the insert with a smaller cutting radius.

Increase the depth of cut.

Change to low RPM

Insert Breaks

RPM too low: Insert under pressure not cutting.

Feed Rate too fast: Insert under pressure not cutting.

Depth of Cut too large: Too much pressure to the insert.

Insert too hard: Hard inserts are very brittle, will break easily.

Increase RPM.

Slow feed rate.

Change to a small depth of cut.

Change to a tougher and impact resistant insert.

ChatteringWrong Insert: Not all the inserts will perform with the Solution Tool!TM

Wrong Boring Bar: Boring bar size must be selected for the boring application.

Wrong Cutting Parameter: Wrong cutting parameter will develop chattering.

The smallest insert angle geometry, high positive with a small cutting radius.

The largest boring bar possible with shorts overhang.

The optimum cutting parameter for the specific insert and operation.

How to Remove ChatteringSlow the RPM, increase fn, and use a high positive rake insert to cut under the chartered surface until the chatter is totally removed, then resume in normal cutting condition.


Solution Tool Boring Bar Roughing Operation Medium Operation Finishing OperationUPC No.

RH LH Description Dia. Ratio Max. Depth ap fn Insert ap fn Insert ap fn Insert

Car

bide

Bar

5.00

”

59400 59401 DVI08X-08-_ _ _ _CB

.500”

8 4.000” 0.040 0.006 CCGT-060204-UEXL-DPC25UT 0.030 0.004 CCGT-060204-UEU-DUP15VT 0.005 0.003 CCGT-060202-NFU-DNX10UT

59034 59035 DVI08X-10-_ _ _ _CB 10 5.000” 0.030 0.006 CCGT-060204-UEXL-DPC25UT 0.020 0.004 CCGT-060204-UEU-DUP15VT 0.004 0.003 CCGT-060202-NFU-DNX10UT



12m

m

59414 59415 DVM12X-08-_ _ _ _ CB

12mm

8 96mm 1.02 0.15 CCGT-060204-UEXL-DPC25UT 0.76 0.10 CCGT-060204-UEU-DUP15VT 0.13 0.08 CCGT-060202-NFU-DNX10UT

59076 59077 DVM12X-10-_ _ _ _CB 10 120mm 0.76 0.15 CCGT-060204-UEXL-DPC25UT 0.51 0.10 CCGT-060204-UEU-DUP15VT 0.10 0.08 CCGT-060202-NFU-DNX10UT



UPC No.RH LH Description Dia. Ratio Max.

Depth ap fn Insert ap fn Insert ap fn Insert

Car

bide

Bar

6.25

”

59404 59405 DVI10X-08-_ _ _ _CB

.625”

8 5.00” 0.050 0.006 CCGT-060204-UEXL-DPC25UT 0.040 0.004 CCGT-060204-UEXL-DPC25UT 0.005 0.003 CCGT-060202-NFU-DNX10UT

59046 59047 DVI10X-10-_ _ _ _CB 10 6.25” 0.040 0.006 CCGT-060204-UEXL-DPC25UT 0.030 0.004 CCGT-060204-UEXL-DPC25UT 0.004 0.003 CCGT-060202-NFU-DNX10UT



16m

m

59418 59419 DVM16X-08-_ _ _ _CB

16mm

8 128mm 1.27 0.15 CCGT-060204-UEXL-DPC25UT 1.02 0.10 CCGT-060204-UEXL-DPC25UT 0.13 0.08 CCGT-060202-NFU-DNX10UT

59088 59089 DVM16X-10_ _ _ _CB 10 160mm 1.02 0.15 CCGT-060204-UEXL-DPC25UT 0.76 0.10 CCGT-060204-UEXL-DPC25UT 0.10 0.08 CCGT-060202-NFU-DNX10UT

59090 59091 DVM16X-12-_ _ _ _CB 12 192mm 0.76 0.15 CCGT-060204-UEXL-DPC25UT 0.51 0.10 CCGT-060204-UEXL-DPC25UT 0.08 0.08 CCGT-060202-NFU-DNX10UT

59092 59093 DVM16X-14-_ _ _ _CB 14 224mm 0.38 0.15 CCGT-060204-UEXL-DPC25UT 0.25 0.10 CCGT-060204-UEXL-DPC25UT 0.05 0.05 CCGT-060202-NFU-DNX10UT

Note: Cutting parameter of the chart has been tested in Dorian Tool facilities and using Dorian Tool inserts grades. The actual parameter will change with the insert used according to the geometry and grade.

Integral Carbide Boring Bar Parameter.

Material 414026/32HRCCutting Speed: SFM 450/700Vc: 136/231 m/min

For Technical Support contact Dorian Tool:615 County Rd 219, East Bernard, TX 77435 USAPhone: 800-627-0266 Fax: 800-508-7055e-mail: [email protected]: www.doriantool.com

MPR08 MV 2016 ST-INT

carbide boring bar - dorian tool · carbide bar 6 x dia., solution tool!™ 8 - 14 x dia. boring...

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