and that the common practice of interpolating with an older machine is a big task. A
frequent mistake is assuming that a sin-gle-point finishing tool will round out the
bore. Truth is, these tools aren’t built to
address the non-roundness issue. They will
likely help, but achieving perfect roundness
with them is unlikely.
To remedy non-roundness, try using twin
cutting boring heads for prep cuts. The
opposing cutting forces guarantee a round
hole so the finish tool has a consistent
amount of stock to work with all the way
around. Tooling balance is crucial to making
a perfect circle, especially in high-speed or
long-reach applications. Choose tools
with balance compensation. The various styles available include tools that
balance automatically with built-in
pinions and those that adjust with a
scale ring on the back side.
Similarly, pay attention to part uniformity. If part of the bore lies along
a very thin wall, it can deform during
cutting. In cases like this, try to reduce
the DOC and take as little stock as
possible on the finishing pass. In turn,
you’ll need to remove more stock in
your previous operation. You can also
try changing to a ground insert that
requires less cutting force.
Also, measuring holes while the part
is still clamped can help to ensure the fix-
turing isn’t deforming the part. Don’t wait
for the CMM to find out that a hole is out of
round and then have to diagnose the issue.
Admittedly, this isn’t always the easiest con-
sidering fixture investments, but it will pay
off in the long run.
Matt Tegelman is product manager (Kaiser)
and applications manager at BIG Kaiser,
Twin cutter boring heads can help achieve hole
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