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Presented by
Sasanka Sekhar Sinha
(2013MEM2622)
Dept. of Mechanical Engineering
Indian Institute of Technology Delhi
Boring Background
Boring operations
post pre-machining, casting, forging, extrusion, flame-cutting, etc.
performed in machining centers and vertical boring machines.
External boring operations can be accomplished using specially adapted boring tools.
Internal machining operations are very sensitive to chatter and vibrations.
Common challenges include:
unfavorable geometric circumstances.
machining at extended length-to-diameter ratios.
provides little space for a stable tool and has restrictions for coolant supply and
chip removal.
These factors can lead to chattering, poor surface finish, noisy vibrations, and work
pieces that are out of tolerance.
The most common size holes being bored are 30 to 100 mm diameter.
Four times the hole diameter is generally the maximum recommended depth.
Damped boring tools (Silent Tools) should generally be considered for hole depths of more
than four times the diameter.
VIBRATIONS IN CUTTING
Three main types of vibration may occur in cutting.
1. Free vibration
2. Forced vibration
3. Self-induced vibration
Basic diagram of
chatter
Maximize Stiffness
The designer of overhung boring bars is often faced with two conflicting requirements:
(1) the bar must be rigid enough to resist chatter and to minimize errors of geometric
form; and
(2) it must be long enough to profile bore deep into the workpiece.
Given a fixed overhang ratio, it is possible to increase the stiffness of the boring bar by
utilizing stiffer materials of high modulus of elasticity.
Tungsten-carbide which has a modulus of elasticity 2.5 to 3 times that of steel is often
used. Nevertheless, in addition to being expensive to manufacture, the tungsten bars are
very brittle and are readily fractured if they are dropped.
It consists of a set of inertial discs made from a type of heavy tungsten alloy, Kennertium .
A tuning mechanism of the inertia mass has been introduced to the boring bar. The
dynamic compliance of the inertia mass which is suspended in the tool cavity by rubber
bushes may be altered by a screw ram, so that for a particular vibratory motion the
response of the inertia mass is tuned to the operating frequency.
The technical problems of Sandvic TNS Bars are as follows :
a) Since the response of a process could change during cutting, in process tuning may not
be possible.
b) The root segment of the bar is made of standard tool steel and makes no contribution
to the overall stiffness of the bar.
The overhanging (free end) segment of the combination structure, on the other hand, is
designed to be light, while no special attention is paid to its Young's modulus, since the
effective structural stiffness does not depend noticeably on the stiffness of the free end
segment.
(a
)
(b
)
Conclusions
The wide variation in chatter frequencies, that occurs when the bar is used over a wide range of cutting
condition and work piece materials, virtually rules out the use of highly tuned spring-type vibration absorber.
The use of impact damper does not provide a satisfactory answer either, due to the fact that the device
operates only when a certain level of vibration is exceeded and even then it serves only to limit the build up
of the amplitude but not to suppress the vibration altogether.
The use of Lanchester damper for the suppression of chatter is a feasible proposal. Such a device possesses a
damping characteristic which is operative over a wide range of frequencies and hence is a suitable candidate
for consideration.
QUESTIONS ??
Thank You
Vernon Devices (3.8) have developed a boring tool that uses an entirely different principle to prevent
vibration as shown in Figures 3.10 (a) and (b). This tool is designed to support a boring bar at the
cutting edge and is reported to be six times as rigid as an unsupported boring bar of similar proportion.
The tool consists of a trueing bit which starts the boring by correcting the initial misalignment and
outof-roundness of the pre-drilled hole. The nose cone which is used to support the bar inside the bore,
contacts the perimeter of the hole;coolant flow begins when the nose cone engages the workpiece.
The boring bit engages the work piece as the nose cone receives
pressure from the internal spring. The boring cutters now receive full
support. The bore bit generates the desired hole in a single path.
Although this is one of the most effective methods of generating good
quality bores, it can also be regarded as one of the most expensive
methods.
There may also be further drawbacks due to:
a) The bore size is limited to the range of the adjusting radius of the
bore bit. Typically 45 - 60 mm.
b) The nose cone is in direct contact with the initial bore, causing
wear on the part which would require frequent maintenance and increase
cost of operation.
c) entrapped chips or debris on the nose cone could cause instability
of the process.