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Types of Boring Bars
Boring bars are cutting tools used on lathes and machining centers to enlarge existing holes or generate new holes with great precision. There are several different types of boring bars, each suited to specific boring applications and capable of producing highly accurate holes.
Roughing Boring Bars
Roughing boring bars have a reinforced rigid construction and are able to take heavy cuts when removing large amounts of material. They use triangular or rhombic shaped inserts with a strong positive rake angle for aggressive cutting. Common materials for rough boring bars include:
- Solid carbide - exceptional rigidity and heat resistance
- Steel or carbide tipped - cost effective option for intermittent rough boring
Rough boring is commonly the first operation done when enlarging an existing hole or generating a new oversized hole. The goal is to quickly remove material to get close to the final dimensions.
Finish Boring Bars
Finish boring bars are precision tools intended for the final sizing of a hole to meet exacting tolerance requirements. Their inserts have geometries suited for light cuts and fine surface finishes. Some features of finish boring bars include:
- High length to diameter ratios for minimizing vibration
- Use of vibration dampening sleeves
- Very rigid construction
- Positive insert geometries for finishes under 16 microinches
The rigidity and stability of finish boring bars is crucial for achieving fine tolerances consistently, as any vibration can produce tapered, bell mouthed, or out-of-round holes.
Deep Hole Boring Bars
Deep hole boring bars allow for internal boring operations down into deep blind holes or through bores. Typical features include:
- Extended bar lengths up to 20x diameter
- Coolant ducts for delivering cutting fluid directly to the inserts
- Replaceable carbide inserts on the pilot end for guiding in existing holes
The extended bar length allows the cutting inserts to reach deep into holes for internal boring. Coolant ducts are critical for chip evacuation and temperature control when the cut is far from the surface.
Back Bored Bars
Back bored bars have cutting inserts arranged at the rear end of the bar near the tool holder. This allows them to be used for back boring applications where the cutting action is on the backside of a hole. Benefits include:
- Ability to back bore close to shoulders
- Direct access to back face surface
- Perpendicular alignment to bore axis
Proper back boring can improve hole geometry and finish for bearing fits or precision mounts. Back bored bars provide an efficient method for accomplishing this type of internal machining operation.
Understanding the different types of boring bars and their characteristics allows the selection of the optimal tool for specific boring needs, whether roughing, finishing, deep hole, or back boring. With the right bar, holes can be produced precisely and efficiently.
Roughing Boring Bars
Roughing boring bars are a type of boring bar used for removing large amounts of material when initially boring a hole or enlarging an existing hole. Their sturdy construction and aggressive cutting geometry make them well-suited for hogging out material quickly and efficiently.
Design and Geometry
The design of roughing boring bars focuses on stability, strength, and rigidity. Features include:
- Large, solid bar diameters
- Minimal overhangs
- Triangle or rhombic inserts with positive rakes up to 45 degrees
- Reinforced bar construction
This type of design allows for very heavy cuts without deflection while clearing chips effectively. The positive rake angles on inserts also promote efficient cutting.
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Materials
Common materials for rough boring bar construction include:
- Solid carbide - highest rigidity and allows fastest metal removal rates
- Steel with brazed carbide tips - cost effective for intermittent rough boring
- Ceramics - increased heat resistance for high temperature alloys
Coatings like TiAlN or TiCN are also often applied to inserts and bars to reduce heat buildup and extend tool life when rough boring.
Uses and Machining Considerations
Typical uses include:
- Enlarging existing holes and bores to remove damaged material or meet a larger dimension
- Boring new oversized holes as an initial operation before finish boring
- Hogging out cavities and pockets in castings
During rough boring, feed rates are maximized to rapidly remove material. However, cutting speeds are kept lower than finish boring to account for the increased forces. Usage of cutting fluid is highly recommended for heat control and chip evacuation.
Rough boring removes the bulk of material before finish boring takes place. This saves significant time compared to just finish boring from a starting hole to final size. By utilizing the proper rough boring bars, large amounts of material can be removed efficiently while still maintaining hole geometry.
Finish Boring Bars
Finish boring bars are precision cutting tools used for sizing holes to meet exacting dimensional tolerances and fine surface finish requirements. Their optimized geometry and rigidity produce the hole roundness, straightness, and finish needed for bearing fits, precision bushings, and close tolerance components.
Design and Geometry
Some key design elements of finish boring bars include:
- High length to diameter ratios (up to 25:1) to resist vibration and deflection
- Preloaded, dampened boring heads to absorb cutting forces
- Positive insert geometries with small radii for light cuts
- Rigid construction using alloys like carbide or ceramics
These features allow finish boring bars to meet hole position tolerances of +0.002" or better consistently even in production environments.
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Achieving Precise Hole Geometry
Proper finish boring technique is required to produce truly round, straight, and dimensionally accurate holes. This involves:
- Taking light depth of cuts under 0.010"
- Using firm but not aggressive feed rates
- Keeping the boring bar centered and supported in the hole
- Applying a steady stream of cutting fluid for lubrication and temperature control
Following these guidelines prevents vibration, deflection, and radial forces which can cause taper, out-of-roundness, or bell mouthing.
Typical Applications
Finish boring excels in applications like:
- Bearing and bushing fits requiring H7 tolerance or better
- Holes for precision locators and dowel pins
- Matching holes for press fits and shrunk fits
- Precision components like hydraulic cylinders, pumps, and compressors
The intersection of high dimensional accuracy and fine surface finish achievable with finish boring is critical for these applications to function properly.
Finish boring bars, with their optimized design for rigidity and precision hole sizing capability, are indispensable tools that allow machinists to routinely generate accurate, straight, and round holes to fine tolerances.
Deep Hole Boring Bars
Deep hole boring bars are specialized tools that allow internal boring operations to be performed deep inside blind holes and through bores that are significantly longer than their diameter.
Design Features
Typical design features of deep hole boring bars include:
- Extended bar lengths up to 20 times the bore diameter
- Coolant ducts running through the bar to deliver cutting fluid
- Replaceable carbide inserts on pilot end to guide bar
- Diameter reduced behind cutting head for clearance
This long, slim design permits the cutting inserts and boring head to reach far into deep holes for internal boring operations.
Boring Application Examples
Deep hole boring is utilized for applications such as:
- Enlarging or straightening gun barrels and actuators
- Precision boring of hydraulic cylinders and shock absorbers
- Machining internal bearing and bushing seats in deep holes
- Sizing oil and gas well equipment bores
The deep reach and precise boring capability expands the range of applications compared to standard length boring bars.
Machining Considerations
Some key considerations when deep hole boring include:
- Hole straightness is critical to guide the bar and avoid binding
- Coolant flow through bar to evacuate chips and control heat
- Entry chamfers to guide pilot end into hole
- Lighter depths of cut due to extended bar length
Proper process planning and technique allows excellent dimensional accuracy and surface finish, even deep inside holes. This expands the possibilities for internal geometries in deep bore applications.
Deep hole boring bars provide access for internal machining operations not otherwise possible. Their specialized design opens up precision boring in blind and through holes far exceeding the standard reach of typical boring bars.
Benefits of Amazon Prime for Buying Boring Bars
Amazon Prime provides several advantages when purchasing boring bars and other cutting tools for manufacturing operations. The benefits include:
Free Two-Day Shipping
Amazon Prime members get free two-day shipping on eligible items including boring bars. This allows you to get the boring bars you need quickly without inflated costs. Rapid fulfillment of boring bar orders helps prevent downtime in production when tools wear out or break.
Free One-Day Shipping
Amazon Prime provides free one-day shipping on millions of items for members in many areas. For urgent boring bar orders, one-day shipping ensures you get replacements even faster to keep machining operations running.
Free Same-Day Delivery
In select metro areas, Amazon offers Prime members free same-day delivery on qualifying orders over $35. This means you can get boring bars delivered the very same day in emergencies to avoid prolonged machine shop downtimes.
Prime Early Access
Amazon Prime Early Access provides members exclusive early access to deals on items like boring bars. This ensures you have first pick of discounted boring bars and cutting tools before non-Prime members.
The fast, free shipping options of Amazon Prime provide convenience and time savings when ordering boring bars and other tooling essentials. Avoiding rush shipping fees also makes Prime very cost effective for manufacturers. The additional perks like Early Access further add value for members.
- Types of Boring Bars
- Roughing Boring Bars
- Finish Boring Bars
- Deep Hole Boring Bars
- Back Bored Bars
- Roughing Boring Bars
- Design and Geometry
- Materials
- Uses and Machining Considerations
- Finish Boring Bars
- Design and Geometry
- Achieving Precise Hole Geometry
- Typical Applications
- Deep Hole Boring Bars
- Design Features
- Boring Application Examples
- Machining Considerations
- Benefits of Amazon Prime for Buying Boring Bars
- Free Two-Day Shipping
- Free One-Day Shipping
- Free Same-Day Delivery
- Prime Early Access
