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Boring troubleshooting

​Boring troubleshooting tips for both rough boring and fine boring, concerning chip breaking, tool vibrations and machine power limitation, are presented below.

 

Rough boring troubleshooting

CauseSolution

​​Chip breaking
Chips too short and hard
  • Feed​ too high
  • Cutting speed​ too low
  • Unsuitable geometry​
  • Decrease feed
  • Increase cutting speed
  • Change geometry to a more open chip breaker

Chip breaking
Chips too long
  • Feed​ too low
  • Cutting speed too high
  • Unsuitable geometry
  • Increase feed
  • Decrease cutting speed
  • Change geometry to a more closed chip breaker

Tool vibration
  • Tool length/coupling size ratio too high
  • Use largest possible coupling size
  • Use/shorten the dampened boring tool
  • Unstable conditions​
  • Ensure rigid clamping with face contact to spindle
  • Use rough boring tool with a two-insert design
  • Check that all units in the tool assembly are assembled correctly, with correct torque
  • Check machine spindle, workpiece clamping, wear, etc.​
  • Feed​ too low
  • Increase feed
  • Feed too high
  • Decrease feed​
  • Speed too high
  • Decrease cutting speed​
  • Cutting depth too large
  • Apply step boring​
  • Cutting force too high
  • Decrease depth of cut
  • Use positive inserts
  • Use smaller nose radius
  • Wiper inserts not recommended for long overhangs or unstable conditions
  • Cutting force too low
  • Increase depth of cut

Machine power
  • Limited machine power​
  • Make sure the machine can provide the required torque and power for the specific boring application, especially when rough boring
  • Decrease cutting data
  • Apply step boring​
 

​Fine boring troubleshooting

CauseSolution

​​Chip breaking
Chips too short and hard
  • Feed​ too high
  • Cutting speed​ too low
  • Unsuitable geometry​
  • Decrease feed
  • Increase cutting speed
  • Change geometry to a more open chip breaker

Chip breaking
Chips too long
  • Feed​ too low
  • Cutting speed too high
  • Unsuitable geometry
  • Increase feed
  • Decrease cutting speed
  • Change geometry to a more closed chip breaker

Tool vibration
  • Cutting force too high
  • Use largest possible coupling size
  • Use a light cutting insert
  • Use smaller nose radius
  • Use sharp cutting edges, uncoated or with thin coating
  • Wiper inserts are not recommended for long overhangs or unstable conditions
  • Use a smaller nose radius
  • Decrease depth of cut
  • Tool length/coupling size ratio too high
  • Ensure rigid clamping with face contact to spindle
  • Use largest possible coupling size
  • Shorten the assembly, if possible
  • Use dampened boring tools
  • Unstable conditions
  • Ensure rigid clamping with face contact to spindle
  • Check that all units in the tool assembly are assembled correctly, with correct torque
  • Check machine spindle, workpiece clamping, wear, etc​.
  • Feed too high
  • Decrease feed​
  • Speed too high
  • Decrease cutting speed​
  • Friction instead of clean cutting action
  • Increase depth of cut

Machine power
  • Limited machine power​
  • Make sure the machine can provide the required torque and power for the specific boring application, especially when rough boring
  • Vibration
  • Reduce speed. See above for additional solutions
  • Feed marks
  • Use a light cutting insert
  • Use larger nose radius
  • Decrease feed​
  • Worn insert​
  • Change cutting edge. For how to avoid specific wear patterns​
  • Chip scratching surface​
  • Improve chip breaking​
 

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