Troubleshooting for Rough Boring

Even the most well-thought-out rough boring process may not achieve the desired result. Under certain conditions, it might be necessary to modify or adapt recommended cutting data or tooling configurations of the application. We’ve provided solutions to common rough boring problems to help get you back on the road to productivity.

Need some help with your fine boring? Check out this troubleshooting guide for fine boring. 

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

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