BIG KAISER High Performance Tooling Solutions 2018-2019

ROUGH BORING HEADS
ROUGH BORING TROUBLESHOOTING
Under certain conditions, it may be necessary to modify or adapt recommended cutting data and/or tooling configurations of
the application. Below are general solutions to common problems.
Problem Possible Cause Remedy
Feed rate too low
Increase feed rate
Poor Chip Control
Excessive height variation of inserts
Width of chip excessive (D.O.C.)
Preset tool to max. .0002" variation of both inserts
Preset tool for stepped cutting method
Excessive stock allowance
Consult cutting data tables
Excessive speed
Reduce SFM, check cutting data tables
Shorten tool to increase stiffness
Extreme length/diameter ratio
Increase boring bar diameter to larger size
Chatter & Vibration
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)
Wrong insert
Change to tougher grade of carbide insert
Use larger radius if available
Inserts Chipping or Breaking
Severe interruption
Increase speed, decrease feed
Chips packing and re-cutting
Check for boring bar/bore diameter clearance
Improve chip control,increase feed
Wrong insert
Change to higher wear resistant grade
Excessive cutting speed
Reduce speed
Poor Tool Life
Inserts chipping
Check stock allowance and feed rate
Chips Not Evacuating
Coolant pressure too low
Boring bar diameter too large
Excessive stock allowance
Inadequate space below bore
Poor chip control
Excessive feed rate
Stock allowance excessive
Increase through tool coolant pressure
Adjust coolant ports of head if available
Reduce to smaller head and extended range holder
Re-set tool for stepped cutting
Elevate workpiece from table more
See above problem
Reduce feed; minimum 25% of insert radius
Reset tool for stepped cutting method
B.1 ROUGH BORING
Insufficient Machine Power
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 feed rate
Reduce feed rate
Excessive Exit Burr
CC type insert holders
Cutting forces too high
Use square insert holders with 6 degree lead
Reduce depth of cut
Reduce insert radius
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