INDEXABLE BORING BAR AND INSERTS FLAT TOP, CHIP CONTROL, CBN, AND PCD

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1 INDEXABLE BORING BAR AND S FLAT TOP, CHIP CONTROL,, AND 80 Diamond.156 IC R DIAMOND FLAT TOP 80 DIAMOND CHIP CONTROL AT ACD5031 ACD5031E AT ACD5071 ACD5071E AT ACD5151 ACD5151E R AT ACD507L2 ACD507L2E AT ACD515L2 ACD515L2E.156 R DIAMOND / TIPPED AT ACD50712 ACD5071 AT ACD51512 ACD Triangle.160 IC R TRIANGLE FLAT TOP 60 TRIANGLE CHIP CONTROL AT ATD5031 ATD5031E AT ATD5071 ATD5071E AT ATD5151 ATD5151E R AT ATD507L2 ATD507L2E AT ATD515L2 ATD515L2E R TRIANGLE / TIPPED AT ATD50712 ATD5071 AT ATD51512 ATD Diamond IC º R R 80 DIAMOND FLAT TOP 80 DIAMOND CHIP CONTROL AT ACP2031 ACP2031E AT ACP2071 ACP2071E AT ACP2151 ACP2151E º AT ACP207L2 ACP207L2E AT ACP215L2 ACP215L2E R DIAMOND / TIPPED AT ACP20712 ACP2071 AT ACP21512 ACP Triangle IC R.096 R.096 R TRIANGLE FLAT TOP 60 TRIANGLE CHIP CONTROL AT ATP2071 ATP2071E AT ATP2151 ATP2151E AT ATP207L2 ATP207L2E AT ATP215L2 ATP215L2E 60 TRIANGLE / TIPPED AT ATP20712 ATP2071 AT ATP21512 ATP2151

TYPES FLAT TOP, CHIP CONTROL,, AND Flat Top Inserts Flat top inserts can be used in right hand and left hand indexable boring bars. The top is polished for maximum chip flow. Options include.003,.

Chip Control Inserts Chip control inserts feature a special ground groove that is effective for either light or heavy depth of cut.

015 corner radii and are stocked in uncoated and AlTiN coated.

The products are precision ground with hones for machining to submicron finishes with maximum tool life. tipped inserts can take the place of grinding.

The products are precision ground for machining to submicron finishes with maximum tool life. tipped inserts allow for higher cutting speeds with longer tool life.

2 TYPES FLAT TOP, CHIP CONTROL,, AND Flat Top Inserts Flat top inserts can be used in right hand and left hand indexable boring bars. The top is polished for maximum chip flow. Options include.003,.007, and.015 for corner radii. Flat top inserts are stocked in both uncoated and AlTiN coated. Chip Control Inserts Chip control inserts feature a special ground groove that is effective for either light or heavy depth of cut. It prevents material from birdnesting [a common problem that often damages surface finish and chips inserts]. Chip control inserts are available with.007 or.015 corner radii and are stocked in uncoated and AlTiN coated. Cubic Boron Nitride () Inserts tipped inserts are recommended for the continuous cutting of a wide range of hardened steels, powdered metals, cast irons and super alloys. The products are precision ground with hones for machining to submicron finishes with maximum tool life. tipped inserts can take the place of grinding. Polycrystalline Diamond () Inserts tipped inserts are excellent for continuous cutting of a wide range of non-ferrous and non-metal materials. The products are precision ground for machining to submicron finishes with maximum tool life. tipped inserts allow for higher cutting speeds with longer tool life. Guidelines for (Ideal for hard ferrous metal -45 Rc plus) Depth of cut should not exceed 30% of tip length. Coolant use is not advised as it could cause thermal cracking Do not stop the machine with the tool in cut - this will result in tool breakage. Make sure the machine and setup is rigid and solid; chatter will cause chipping. Tool height when boring should be slightly above center; tool deflection will put the tool on center. Do not contact the tool to a hard surface prior to the machining process - this will cause chipping. Guidelines for (Ideal for non-ferrous materials) Higher speeds minimize tool buildup. Depth of cut should not exceed 70% of tip length. Use of coolant will reduce heat and improve surface finish. Do not stop the machine with the tool in cut - this will result in tool breakage. Make sure the machine and setup is rigid and solid; chatter will cause chipping. Tool height when boring should be slightly above center; tool deflection will put the tool on center. Do not contact the tool to a hard surface prior to the machining process - this will cause chipping.

3 INDEXABLE BORING BAR FEED AND SPEED CHART FOR FLAT TOP & CHIP CONTROL S FLAT TOP AND CHIP CONTROL S MATERIAL HB/Rc SPEED RANGE (SFM) ALTIN+ ACD & ATD ATP & ACP FEED IPR CAST IRON 160 HB CARBON STEEL 18 Rc ALLOY STEEL 20 Rc TOOL STEEL 25 Rc STAINLESS STEEL 150 HB STAINLESS STEEL 195 HB HIGH TEMP ALLOY (Ni & Co BASE) 20 Rc TITANIUM 25 Rc HEAT TREATED ALLOYS (38-45Rc) 40 Rc ALUMINUM 100 HB BRASS, ZINC 80 HB SFM = Surface Feet per Minute Starting parameters only. Length to diameter ratios, setup, and machine rigidity may affect performance. The max Depth Of Cut (DOC) acceptable at the minimum Inches Per Revolution (IPR).

4 INDEXABLE BORING BAR FEED AND SPEED CHART FOR -TIPPED AND -TIPPED S TIPPED S MATERIAL BHN/Rc FEED IPR SPEED RANGE (SFM) ACD & ATD ATP & ACP HEAT TREATED ALLOY Rc TOOL STEEL Rc NODULAR IRON N/A PEARLITIC IRON BHN WHITE/CHILLED IRON Rc SUPER ALLOY Ni BASE BHN COBOLT BASED ALLOY, STELLITE Rc INCLS Rc TIPPED S MATERIAL BHN/Rc FEED IPR SPEED RANGE (SFM) ACD & ATD ATP & ACP LOW SILICON ALUMINUM BHN HIGH SILICON ALUMINUM BHN METAL MATRIX COMPOSITES COPPER ALLOYS, BRASS, BRONZE PRESINTERED TUNGSTEN CARBIDE N/A BHN BHN ACRYLICS N/A FIBERGLASS N/A GRAPHITES N/A NYLON, PLASTIC N/A HARD RUBBER N/A

5 INDEXABLE BORING BAR TROUBLESHOOTING PROBLEM CAUSE SOLUTION Reduce the cutting speed. RAPID FLANK WEAR Select a coated grade. HEAT Use the SCT coolant holder. If coolant is not available, use shop air and a coated tool. Use a coolant through boring bar. Select a coated grade. BUILT-UP EDGE CUTTING FORCE Use chip control insert to free up cut. HEAT Use coolant through boring bar or holder. If coolant is not available, use shop air and a coated tool. Use coolant through boring bar. Reduce depth of cut. Reduce feed rate. BREAKAGE Select a larger corner radius PART Check the drilled hole to make sure the full diameter of the drill is deeper than the programmed bore depth. SURFACE TOO ROUGH CHATTER SETUP BORING BAR Reduce feed rate. The rate is too great for the nose radius. Select a larger corner radius. The feed rate (IPR) should not be greater than 1/2 the nose radius. Set insert above center. Change the speed of the machine. The overhang ratio should be less than 8x bar diameter for carbide. Clamping length should be at least 3x the boring bar diameter. Select the largest diameter bar that will bore the required diameter. CUTTING FORCES Forces may deflect bar below center causing the hole to become larger. TAPER BIGGER IN BACK TAPER SMALLER IN BACK BUILT-UP EDGE PROGRAM CHIP PACKING PROGRAM A built-up edge will cause the hole to become large until the built-up edge breaks off, then hole will be smaller. If the taper is consistent (not from chip packing) then the program can be altered to bore a taper in opposite direction resulting in a straight hole. If the boring bar is too large to allow chips to evacuate then the chips may pack on the insert and cause the bar to deflect away from the bore. If the taper is consistent (not from chip packing) then the program can be altered to bore a taper in opposite direction resulting in a straight hole.

INDEXABLE BORING BAR DEFLECTION Force L Bar Deflection: F L 3 3.14 D I = 4 3 E I 64 F = Cutting force (lbs) L = Overhang (in.

This force can deflect the cutting edge below the centerline of the part, resulting in incorrect bore size. To minimize deflection, the length of overhang should be kept as short as possible.

6 INDEXABLE BORING BAR DEFLECTION Force L Bar Deflection: F L D I = 4 3 E I 64 F = Cutting force (lbs) L = Overhang (in.) E = Coefficient of Elasticity of Bar Shank D = Tool Diameter I= Moment of Inertia The greatest amount of force on the boring bar is on the top of the cutting edge. This force can deflect the cutting edge below the centerline of the part, resulting in incorrect bore size. To minimize deflection, the length of overhang should be kept as short as possible. As shown in the formula, the length of overhang is multiplied to the third power, and the diameter is multiplied to the fourth power. This means that a small change in length of overhang or bar diameter can make a large difference in deflection. Using the largest diameter bar with the least amount of overhang as possible gives the best chance of successful boring operations. The picture shows the boring bar in a coolant holder. Coolant or shop air provided to the holder will cool the insert and part and evacuate chips from the hole.

METRIC THREAD MILLS SINGLE PROFILE (SPTM) - SOLID CARBIDE. Scientific Cutting Tools, Inc. Q A C OAL 60º THREAD MILLS METRIC

METRIC THREAD MILLS SINGLE PROFILE (SPTM) - SOLID CARBIDE. Scientific Cutting Tools, Inc. Q A C OAL 60º THREAD MILLS METRIC METRIC SINGLE PROFILE (SPTM) - SOLID CARBIDE METRIC Q A B 60º C S With just 19 varieties of Thread Mills, fine and coarse threads ranging from M1.2 to M30+ can be milled SPECIALTY PORT - CAVITY INDEXABLE