Category: Boring

The new DR-Large reaming system: Modular Reaming for Large Bores

6/14/2022

Horn USA has introduced the new DR-Large modular reaming system for use in the machining of large bores.

Horn USA REAMING SYSTEM DR large Modular reaming for bore diameters up to 200 mm

The latest DR tool offers easy handling and high-precision thanks to the proven technology of the DR system. The large number of cutting edges and high feed rates reduce cycle time and machining costs.

Modular construction and solid carbide inserts offer the user exceptional flexibility. Tool setting is not necessary when exchanging the cutter’s head as HORN offers reconditioning service for the DR-Large system.

The versatile and powerful interchangeable high-feed reamer is perfectly suited for finishing large bores from Ø140 mm (5.512”) to Ø200.2 mm (7.881”).

The modular construction of the reaming tools can be extended to any length with beta module standard components. The beta module interface is ABS-compatible. HORN offers six types of cutter heads to cover the entire range of diameters in 10 mm (.394”) increments.

All cutter heads are manufactured with internal through coolant to each cutting edge. The custom insert interface offers extreme precision and insert interchangeability within microns.

High-precision, high-feed reaming is a very economical machining process compared to the boring of tight tolerance holes.

The motivation behind DR-Large is the customer demand to replace large diameter tools with inserts brazed into a fixed position and tools that are diameter specific.

The fixed tools require delicate handling, are often heavy, require skilled users, and present logistical challenges when replacing worn tools. HORN offers a perfect solution with the DR-Large pre-calibrated exchangeable reaming head.

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The 7 Most Common Deep Hole Boring Problems and Solutions

3/22/2022

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Dorian Tool has some very detailed technical information in their Solution Tool catalog to address deep hole boring. First we're going to list the fundamental rules of selecting the correct boring bar and then take a deeper dive into the fundamentals of troubleshooting.

If you want more information, technical specifications and much more detailed information on troubleshooting you can download the Solution Tool catalog below.

DEEP HOLE BORING
SELECTION CRITERIA

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 possible 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 and the shortest overhang possible to maximize cutting stability and minimize vibration.
The selection and use of the right insert grade, geometry, 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 material machined in accordance of the insert manufacturing cutting data.
The hole, while machined has to be kept clear from chips to avoid tool breakage, boring bar vibration and the walls of the work piece undamaged.

7 MOST COMMON
DEEP HOLE BORING PROBLEMS

Poor Surface Finish, Poor Machining Tolerance & Poor Insert Life are the issues that every shop faces with cutting tools. Deep hole boring is no different. Below are some rule of thumb for a quick solution. As we said above, be sure to download the Solution Tool Catalog for much more technical information and solutions.

Boring Bar Cutting Ratio: If the incorrect boring bar cutting ratio is used, the boring bar will vibrate.
Boring Bar Diameter: Too small boring bar diameter will deflect under pressure and vibrate, too large boring bar diameter, will obstruct the evacuation of the chips.
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.
Boring Overhang: When the boring bar is over extended it will vibrate (Steel bar 4 x Dia., Carbide bar 6 x Dia.,Solution Tool!™ (The NO! Vibration Re-Tunable Boring Bar) 8 - 14 x Dia.
Incorrect Insert: Incorrect insert geometry, nose radius, rake angle, chip breaker, and clearance angle will cause vibrations.
Cutting Parameter: 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.
Chip Clogging: When chips are clogged into the work piece bore, jamming the insert, wrapping around the boring bar, and thrown against the wall, the insert will be damaged.

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Technical advancements in Deburring over the past 100 years.

6/19/2019

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A short history about deburring from E-Z Burr.

Burrs may be the last concern that an engineer or machinist wants to think about in designing a new part focusing on tolerances and production rate. However, the problem remains and calls for attention to develop a quality product. It was nearly a century ago that a solution was discovered and the first deburring tool went to market.

The first machine driven deburring tool patent was filed in 1911 by F.A. Pica patent # 1,008,363. The original tool was an adaptation of a boring bit to accommodate a countersink portion on the backside of the hole.

To set or activate the deburring process was a laboring process. After boring each hole the machinist must stop the spindle, move a mechanism to engage the deburring insert, start the spindle to begin the deburring process and then again, stop the spindle and disengage the insert and retract.

The size and consistency of the countersink was somewhat guesswork at the time, but ultimately did the job.

In 1943 hole deburring saw the first dramatic update when A. Fried separated the boring and deburring process with patent # 2,314,084.

This helped to achieve a higher quality and accommodate the higher production volumes of the day.

This improved the machining process which could be set to perform desired deburring operations.

But with this tool the cutter still had to be projected and retracted by hand which still made it labor intensive.

The onset of 1950’s led to many updates in deburring leading up to the high volume production requirements of today.

It was in 1952 when the most notable change was by S.A. Cogsdill. He eliminated the hand operated deburring process and provided an adjustable tool with his patent # 2,620,689. This tool can be set to perform desired chamfer sizes and is activated by a spring and plunger, taking the hand operation out of the process.

With this improvement, deburring became an automated process.

Today’s tools offer many solutions to accommodate the many varieties of applications and materials. Looking at the technical aspects of each application, material and individual customer’s goals, E-Z Burr has taken the process of deburring to the next level.

Since 1960, E-Z Burr has been providing innovative and versatile deburring solutions for customers. Over the last 5 years they have introduced and expanded their Carbide Series of deburring tools to produce successful results on hard to machine materials and higher production volumes. “From the very start, our goal has been to provide tools that are durable, dependable, easy to use and maintain, while offering our customers a fair and reasonable price,” says Bill Robinson, President of E-Z-Burr. “We are always looking for new, innovative ways to meet the needs of our customers.”

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The new DR-Large reaming system: Modular Reaming for Large Bores

The 7 Most Common Deep Hole Boring Problems and Solutions

DEEP HOLE BORING
SELECTION CRITERIA

7 MOST COMMON
DEEP HOLE BORING PROBLEMS

Technical advancements in Deburring over the past 100 years.

ABOUT

Archive

Categories

The new DR-Large reaming system: Modular Reaming for Large Bores

The 7 Most Common Deep Hole Boring Problems and Solutions

DEEP HOLE BORING SELECTION CRITERIA

7 MOST COMMONDEEP HOLE BORING PROBLEMS

Technical advancements in Deburring over the past 100 years.

ABOUT

Archive

Categories

DEEP HOLE BORING
SELECTION CRITERIA

7 MOST COMMON
DEEP HOLE BORING PROBLEMS