PRESENTATION ABOUT VERTICAL BORING MACHINES AND HORIZONTAL BORING MACHINES ME 124 MACHINE SHOP THEORY BSME-2 BORING OPERATIONS • • • Boring Operation is equivalent to turning , but it is performed exclusively on internal surfaces. In internal turning, or Boring, the choice of tool is very much restricted by the workpiece’s hole diameter and length. Finish boring is particularly noted for its ability to achieve dimensional and surface. • • • General rule which applies to all machining, is to minimize the tool overhang to obtain the best possible stability and accuracy. With boring the depth of the hole determines the overhang. The stability is increased when a larger tool diameter is used, but even then, the possibilities are limited since the space allowed by the diameter of the hole in the work piece must be taken Into consideration for chip evacuation and radial movements. • Because of the limitations on tooling design imposed by the fact that the work piece mostly surrounds the tool, boring is inherently somewhat more challenging than turning, in terms of decreased tool holding rigidity, increased clearance angle requirements, and difficulty of inspection of the resulting surface (size, form, surface, roughness). BORING OPERATIONS • By understanding how cutting forces are affected by the tool geometry and the cutting data chosen, and also understanding how various types of boring bars and tool clamping will affect the stability, deflection and vibration can be kept to a minimum. HORIZONTAL BORING MACHINE • It is a machine tool which bores holes in a horizontal direction. CUTTING FORCES • TANGENTIAL FORCE • FEED FORCE • RADIAL FORCE CUTTING FORCES • TANGENTIAL FORCE is the largest among the them. It acts perpendicular to the cutting insert rake surface. • TANGENTIAL FORCE will try to force the tool downward and away from the centerline. • Because of the curving of the internal hole diameter the clearance angle will also be reduced. CUTTING FORCES • Therefore, with small diameter holes, it is particularly important that the clearance angle of the insert be sufficient to avoid contact between the tool and the wall of the hole. CUTTING FORCES • FEED FORCE is the second largest . • It acts parallel to the centerline and does not deflect the boring bar. • Typically, the strength of the feed force is about 50 to 60 percent of the tangential force. CUTTING FORCES • RADIAL FORCE is the third among the three forces. • RADIAL FORCE is perpendicular to both of these forces and pushes the bar away from side of the bore. • This force is about 25 to 30 percent of the tangential force. • RADIAL DEFLECTION will reduce the cutting depth. • It can also affect the diametrical accuracy, the chip thickness will change with the varying size of the cutting forces. • If the cutting edge transferred to the tool holder it will lead to vibration. • The stability of the tool and clamping will be the factor that determines the magnitude of the vibration and whether it is amplified or dampened. INSERT GEOMETRY • The geometry of the insert has a decisive influence on the cutting process. • A positive insert has a positive rake angle, the inserted edge angle and clearance angle is equal to less than 90 degrees. INSERT GEOMETRY • Inserted rake angle means a lower tangential cutting force, however positive rake angle is obtained at the cost of the clearance angle or edge angle. • If the clearance angle is small there is a risk of abrasion between the tool and work piece, and friction can give rise to vibration. • A sharper cutting edge is obtained if the rake angle is large and edge angle is small, The sharp cutting edge penetrates the material more easily, but it is also more easily changed or damaged by edge or other uneven wear. • Edge wear means that the geometry of the insert is changed, resulting in reduction in the clearance angle. • In finish machining, it is the required surface finish of the work piece that determines when the insert must be changed. • Edge wear should be between 0.004 and 0.012 in. for finishing and between 0.012 and 0.040 in. for rough machining. LEAD ANGLE • The lead angle effects the axial and radial directions of the cutting forces. • A small lead angle produces a large axial cutting force component while a large lead angle results in a larger cutting force in the radial direction. • Axial cutting force has a negative effect on the operation since the force is direct along the boring bar. • To avoid vibrations, choose small lead angle but, the lead angle also affects other factors such as chip thickness and the direction of the chip flow, so that compromise has to be made. • Small lead angle has also a disadvantages, cutting forces are distributed over a shorter section of the cutting edge than the large lead angle. NOSE RADIUS • The nose radius, is the key factor in boring operations. • The selection of nose radius depends on depth of cut the feed, and influences the surface finish, chip breaking and insert strength. • The relationship between nose radius and depth of cut effects vibration tendencies. CHIP BREAKING AND EVACUATION • Chip breaking is affected by a number of factors such as the insert geometry, nose radius, lead angle, cutting depth, feed and cutting speed. • Make sure chip breaking and evacuation are satisfactory. CHIP BREAKING AND EVACUATION • Chip jamming affects hole quality, reliability and tool life, insert geometry and cutting data is crucial. • Therefore, it is necessary to choose a grade and insert geometry that work together with selected machining parameters, fulfills the requirements for good chip control. BORING RIGIDITY • The key to productivity in boring operations is the tool’s rigidity. • Boring bars are often required to reach long distances into parts to remove stock. • Hence, the rigidity of the machining operation is compromised because the diameter of the tool is restricted by the hole size and the need for added clearance to evacuate chips. • The practical overhang limits for steel boring bars is four times their shrank diameter. • When the tool overhang exceeds this limit, the metal removal rate of the boring operation is compromised significantly because of lack of rigidity and the increased possibility of vibration. BORING BAR DEFLECTION • The size of the boring bar’s deflection is dependent on the bar material, the diameter, the overhang and size of the radial and tangential cutting forces. • Choosing a boring bar made of a material that has higher coefficient of elasticity can also counteract deflection. • Since steel has a lower coefficient of elasticity than cemented carbide, cemented carbide boring bars are better for large overhangs. • Tangential deflection means that the insert tip is moved in a downward direction away from the centerline. • In both case the size direction of the cutting forces are affected by changes in the relationship between the chip thickness and insert geometry. • If the exact size of the deflection of the insert tip is known in advance, then the problem can be avoided. • In the same way, setting the machine at a cutting depth that is greater than the desired cutting depth compensates for the radial deflection. • The practical outcome will be somewhat different because the clamping is never absolutely rigid and because it is impossible to calculate the cutting force exactly. MACHINING • It is a process of cutting, shaping, or removing material from a work piece using a machine tool BORING BAR CLAMPING This Photo by Unknown author is licensed under CC BY-SA-NC. BORING BAR CLAMPING The slightest amount of mobility in the fixed end of the boring bar will lead to deflection of the tool. The best stability is obtained with a holder that completely encases the bar. Holder is available in two style: • A rigid or flange mounted bar • A divided block that clamps when tightened. Less efficient are those tool clamping methods in which the screw clamps onto the bar. This form generally results in vibration and is not recommended. This method most not be used for the clamping of cemented carbide bars. Cemented carbide is more brittle than steel and cracks will occurs as a results of vibration, which in turn may result in breakage. BORING BAR CLAMPING • With a rigidly mounted bar, the bar is either preshrunk into the holder and/or welded in. • With flange mounting, a flange with a through hole is normally used. • The flange is usually glued onto the shank of the bar at distance that gives the required overhang. • The bar is then fed into the holder and clamped by means of screw connection or by being held in the turret. BORING BAR CLAMPING • Less efficient are those tool clamping methods in which the screw clamps onto the bar. • This form generally results in vibration and is not recommended. • This method most not be used for the clamping of cemented carbide bars. • Cemented carbide is more brittle than steel and cracks will occurs as a results of vibration, which in turn may result in breakage. BORING BAR • Boring bars are made in a wide variety of styles. • Single-point boring bars are easily ground but difficult to adjust when they are used in turret and automatic lathes and machining centers, unless they are held in an adjustable holder. BORING BAR • More expensive boring bars are provided with easily adjustable inserts. • These bars are made in standard sizes, with a range of 0.25 to 0.5 in. on the diameter. • A fine adjustment is included in increments of 0.001 in., or in some cases 0.0001 in. They are standard up to about 6 in. in diameter. • Many times, it may be economical to order special bars with two or more presets diameters, set at the proper distance apart. BORING BAR • These special bars cost more and are generally only used when large quantities make their use economical. • Sometimes this may be the only way to hold the required tolerances and concentricity. • Other special boring bars, sometimes called boring heads, are designed with replaceable cartridges. BORING BAR TYPES • Boring bars are available in steel, solid carbide, and carbide-reinforced steel. • The capacity to resist deflection increases as the coefficient of elasticity increases. • Since the elasticity coefficient of carbide is three times larger than that of steel, carbide bars are preferred for large overhangs. BORING BAR TYPES • The disadvantage of carbide is its poor ability to withstand tensile stress. • For carbide-reinforced bars, the carbide sleeves are prestressed to prevent tensile stresses. • Boring bars can be equipped with ducts for internal cooling, which is preferred for internal turning. BORING BAR TYPES • An internal coolant supply provides efficient cooling of the cutting edge, plus better chip breaking and chip evacuation. • In this way a longer tool life is obtained and quality problems, which often arise because of chip jamming, are avoided. BORING BAR CHOICE • When planning production, it is very important to minimize cutting forces and to create conditions where the greatest possible stability is achieved so that the tool can withstand the stresses that always arise. The length and diameter of the boring bar will be of great significance to the stability of the tool. • Since the appearance of the workpiece is the decisive factor when selecting the minimum overhang and maximum tool diameter that can be used, it is important to choose the tool, tool clamping and cutting data which minimize, as much as possible, the cutting forces which arise during the operation. BORING BAR CHOICE • The following recommendations should be followed to obtain the best possible stability: • Choose the largest possible bar diameter, but at the same time ensure that there is enough room for chip evacuation. • Choose the smallest possible overhang but, at the same time, ensure that the length of the bar allows the recommended clamping lengths to be achieved. • A 0-degree lead angle should be used. The lead angle should, under no circumstances be more than 15 degrees. BORING BAR CHOICE • The index able inserts should be positive rake that results in lower cutting forces. • The carbide grade should be tougher than for external turning in order to withstand the stresses to which the insert is exposed when chip jamming and vibration occur. • Choose a nose radius that is smaller than the cutting depth. VERTICAL BORING MILL VERTICAL BORING MILL • A vertical boring mill is a type of large machine tool designed to machine large, heavy workpieces that are difficult to handle on conventional machine tools. • These mills operate somewhat like a very large lathe, standing tall and typically requiring a sturdy foundation to support their weight and operation. VERTICAL BORING MILL FUNCTIONS • Boring: The primary function is boring holes into various materials. These machines can bore precise, large-diameter holes in heavy workpieces. • Turning: Vertical boring mills can perform turning operations, where the workpiece rotates against a stationary cutting tool, creating cylindrical shapes. • Facing: These mills can perform facing operations to create flat surfaces on the end of a workpiece. VERTICAL BORING MILL FUNCTIONS • Cutting Internal and External Threads: The machine can be used for threading operations, both internally and externally. • Drilling and Reaming: Additional operations such as drilling and reaming can also be performed. TYPES OF VERTICAL BORING MILLS 1. Turret Mill - it has a table that moves while the cutting part stays still. It’s pretty handy for certain jobs. 2. Ram-Type Mill - the cutting part can move forward and backward, giving it a bit more reach. ADVANTAGES OF VERTICAL BORING MILLS Vertical boring mills offer several advantages that make them a go-to choose for many machining tasks. Here are the main advantages of using a vertical boring mill: • Handling Large Workpieces • Precision and Accuracy • Accessibility and Operator Visibility • Efficiency and Time Savings • Customization Opportunities SELECTING THE RIGHT VERTICAL BORING MILL Factors to Consider: Size, Capacity, Features Selecting your mill is like choosing your battle gear. • The physical size of the mill is crucial — it needs to fit into your workspace and accommodate the size of your intended workpieces. • Evaluating the weight capacity of the mill’s table and the depth, diameter, and height of the cuts it can make will ensure that the machine meets your production needs. • Also, a close look at the features is essential. Opt for a mill equipped with an advanced, userfriendly control system, a variety of speed settings to adapt to different materials and tasks, and a wide range of tooling options for enhanced versatility. OPERATING PRINCIPLES AND SAFETY BASIC OPERATION STEPS AND PROCEDURES Like a well-executed battle plan, operating a vertical boring mill is about strategy and precision. From setup to execution, every move matters: Setup: 1. Secure the workpiece on the table, ensuring it is properly aligned. 2. Select the appropriate cutting tool and install it. 3. Set the initial tool position and calibrate the machine settings. Programming: • Input the necessary program or G-code, specifying cutting speeds, feed rates, and tool paths. BASIC OPERATION STEPS AND PROCEDURES • Test Run: • Perform a test run with the spindle off to verify the tool path and check for any potential collisions. • Machining: • Turn on the spindle and coolant, then start the programmed operation. • Monitor the machining process, adjusting as necessary. • Inspection and Finishing: • Once machining is complete, turn off the mill and inspect the workpiece. • Perform any necessary finishing operations, such as deburring. TURNING TURNING What is turning? Turning is a machining process that’s characterized by the use of a stationary, non-rotating cutting tool to remove material from the external surface of a workpiece. Although it can be performed by hand, turning is typically performed using a machine known as a lathe. As the workpiece rotates against the blade, the cutting tool removes a uniform amount of material, thereby reducing the size and changing the shape of the workpiece. HORIZONTAL TURNING Horizontal turning centers are the more prominent type across most industries. They have a spindle that is horizontally oriented, with tools mounted out of the side of the tool holder. This helps them cut across the object being processed. HORIZONTAL TURNING Much like it’s the milling counterpart, this type of turning center also benefits from gravity as it pulls the chips away from the work-piece. VERTICAL TURNING • Vertical turning centers are also called vertical turret lathes or VTL. The vertical and horizontal turning centers are very similar, but their configuration and shape are upended allowing the headstock to sit on the floor and the faceplate to become a horizontal rotating table. VERTICAL TURNING • Inverted vertical turning centers are like the regular ones but they have reversed positions for the spindle and jaw chuck. HORIZONTAL BORING M AC H I N E HORIZONTAL BORING MACHINE • The boring machine is one of the most versatile machine tools used to bore holes in large and heavy parts such as engine frames, steam engine cylinders, machine housing, etc. • Which are practically impossible to hold and rotate in an engine lathe or in a drill machine. Therefore, this is the main purpose for which the boring machine was developed. • In addition to its primary purpose of boring, the range of speeds and feeds provided to the various traversing parts allow drilling, milling, and facing to perform with equal facility. HORIZONTAL BORING MACHINE • By the fitting of simple attachments, the use of the machine can extend still further to include screw cutting, turning, planetary grinding, or gear cutting. • In types of boring machines, the horizontal boring machine is one of the most useful and important machines. Let’s first understand the parts of a horizontal boring machine before moving on to the different types of boring machines. PARTS OF HORIZONTAL BORING MACHINE HORIZONTAL BORING MACHINE PRIMARY PARTS • Bed The bed is that part of the machine which is fitting on the floor of the shop and has a boxlike casting. The bed supports the columns, tables, and other parts of the machine. • Headstock Supporting Column The column provides support to the headstock and guides it up and down accurately by the guideways. The column has hollow houses and is heavily ribbed to add rigidity. HORIZONTAL BORING MACHINE PRIMARY PARTS • End Supporting Column The end supporting column is situated at the other end of the bed houses. The column may be adjusted on the slideways of the bed towards or away from the spindle to support the different lengths of boring bars. It may be moved at right angles to the spindle as in the case of a floor-type machine. • Headstock The headstock mounting on the column supports, drives, and feeds the tool. A headstock may move up and down on the column to set the tool for different heights of the work. HORIZONTAL BORING MACHINE PRIMARY PARTS • Saddle and Table The tables serve as work surfaces and have T-slots for holding various devices. The saddle allows the work to be moved longitudinally on the bed. These movements may be slow or rapid and are performed by hand or power. • Boring Bars The boring bar supports the cutter for holding operations on jobs having large bore diameters. For short holes, the bar may support the headstock spindle end only. For long work, the bar is supported on the spindle end and on the column-bearing block. TYPES OF HORIZONTAL BORING MACHINES 1. Table Type Horizontal Boring Machine The table types are the most common of all horizontal boring machines. The name horizontal boring machine is given because the work is mounted on the table which is adjustable and feeds are given by hand or power, lengthwise or crosswise with respect to the bed of the machine. This type of machine is appropriate for generalpurpose tasks where it is necessary to carry out more operations in addition to boring. TYPES OF HORIZONTAL BORING MACHINES 2. Floor Type Horizontal Boring Machine The floor-type horizontal boring machine has notable uses a constant floor plate on which Tslots are provided to hold the work. The headstock supporting column and the end supporting column are mounted on the runways which are placed at right angles to the spindle axis. This is designed for holding very large and heavy workpieces that are difficult to mount and adjust on a table. TYPES OF HORIZONTAL BORING MACHINES 3. Planer Type Horizontal Boring Machine The planer-type horizontal boring machine resembles the table type, but the table slides directly on the bed instead of on a saddle angle to the spindle similar to a planer. The end of the supporting column and headstock supporting column may adjust towards or away from the table to accommodate different widths of work. This type of machine is suitable for supporting a long work. TYPES OF HORIZONTAL BORING MACHINES 4. Multiple Head Type Horizontal Boring Machine The machine resembles a double housing planer or a Plano-miller. The table is supported by a long bed on which it reciprocates. There are two vertical columns at two sides of the bed, nearly in the middle of the bed. The two columns are bridged by a cross rail. The machine may have two, three, or four headstocks. This type of machine may be used as a horizontal and vertical machine. BORING TOOL MOUNTINGS FOR HORIZONTAL BORING 1. Boring bar Ordinary boring operations are carried out with tools mounted on a bar held in a spindle having a morse taper hole. The maximum diameter of the bar employed is ordinarily not larger than the spindle diameter, and the length is such that it can reach the end column support. A boring bar should be of the maximum diameter and minimum length to reduce bending or vibration and it may be supported in various ways to suit to different types of workpieces. BORING TOOL MOUNTINGS FOR HORIZONTAL BORING 2. Boring Head or Cutter Head The boring head is using for mounting cutters while machining large diameter holes where a standard boring bar is unsuitable due to the smaller diameter or excessive overhang of the cutter. Boring heads have the maximum permissible diameter. This device amply supports the tool and reduces machining time due to the larger number of cutting edges. The cutters may adjust by micrometre dials. it illustrates in the boring head. BORING TOOL MOUNTINGS FOR HORIZONTAL BORING 3. Facing head The facing head is mounting on the end of the spindle. It comprises a flange provided with a diameter slide-way on which the tool carrying a bracket may be adjusted. The bracket may be fed radially or located and clamped at the center to support a long boring bar. A facing head enables the enlarging of large diameter holes, facing an external turning operation. it is illustrated in the facing head. ADVANTAGES OF HORIZONTAL BORING MACHINE The following are the advantages of a horizontal boring machine: 1. Some horizontal boring machines have the advantage of producing very large machined parts. 2. Depending on the machine, horizontal boring machines can make several cuts simultaneously and run at a high cutting speed. 3. This is especially helpful in situations where businesses need to produce and deliver a lot of mechanical parts quickly. ADVANTAGES OF HORIZONTAL BORING MACHINE 4. The horizontal boring machines are designed to guarantee that the drilling is always reliable and precise. 5. Horizontal boring machines with computer controls minimize the possibility of human error and guarantee consistently precise cuts. HAZARDS AND RISKS HAZARDS AND RISKS • The principal hazards when working at or near these machines are mechanical in nature. • A review of the accident history shows that the single largest cause of serious injury is entanglement at revolving tools. • Entanglement also accounts for most fatalities, particularly at larger machines. HAZARDS AND RISKS • Crushing and trapping hazards have also been identified as very significant causes of injury. • Most injuries occur during activities such as setting/ adjustment, swarf removal or observation for the purpose of process control. • Injuries are often very severe and include limb and skull fractures and amputations. The potential for fatal injury at these machines should not be underestimated. HAZARDS AND RISKS • Reports of investigated accidents show guarding standards to be generally unsatisfactory with an over-reliance on systems of work and the 'skill' of operators as the principal means of risk reduction. • The precise combination of safety measures adopted will depend upon the outcome of the risk assessment and, in some cases, the practicability of carrying out modifications. • Particularly, care needs to be taken when selecting the control measures. HAZARDS AND RISKS • The final design of the safeguarding arrangements should take into account the need for observation, adjustment etc. while still providing for adequate levels of protection. • A distinction should be made between 'normal' machining operations and those occasions when access to the work zone may be necessary for the kinds of higher-risk activities. SAFEGUARDING • The variation in size and configuration of machines and the specific applications to which they may be put precludes the use of a standard safeguarding solution such as that which may, for example, be applied to most lathes. PRIMARY SAFEGUARDS • The hierarchy of controls prescribed under regulation 11 of PUWER should be applied. During normal machining operations access to the work zone should be prevented by fixed and/or interlocked guards. • The height, position and construction of any new guards should meet appropriate standards. If physical guarding is not practicable alternative types of safety device may be used, example light curtains or pressure mats. BRAKES • It is not possible to specify a minimum stopping performance for braking systems. This is because of the wide range of machine sizes and other design characteristics. • Nevertheless, the objective should be to stop the machine as quickly as possible considering the circumstances. • Where brakes are fitted to older machines, care should be taken to ensure that the machine can withstand the stresses induced by the effects of braking. BRAKES • A braking system may be mechanical or electrical or a combination of both. Preference should be given to disc or caliper brakes in mechanical braking systems. • Advice should normally be sought from the machine manufacturer before modifications are carried out. SUPPLEMENTARY SAFEGUARDS • Where powered movement of machine elements is necessary for setting purposes etc., and access is required by the operator to the work zone, the risks can be reduced by using supplementary safeguards. • The primary safeguard, guard interlocking, can be suspended via a key-operated selector switch. • Any further hazardous movement of the machine element should be achieved by using a hold-to-run control arrangement or enabling device. SUPPLEMENTARY SAFEGUARDS • The selector switch should also enable the braking arrangements, example dc injection braking. On release of the hold-to-run control (or enabling device) the braking system should be applied. • This principle may be incorporated into an existing pendant control. These aspects of the control system are safety-critical and should be designed to meet the requirements of regulation 18 of PUWER. TRAINING The provision of information, instruction and training is a legal requirement. Those matters which require particular attention include: • • • • • • Dangers at the machine Location and operation of controls Precautions to reduce the risk of entanglement Correct use of guards and other safety devices Any tests, example daily test of trip devices, and the system for reporting defects Safe systems of work for cleaning, maintenance, setting and adjustment, loading of workpieces etc. TRAINING • Activities such as swarf removal should normally be carried out with the spindle stopped. • The selection and use of suitable work wear and other personal protective equipment, example for eyes, is important to help minimize other residual risks. MEMBERS: PERLAS, JOHN PAUL S. MAGO, JOHN PAOLO BATOON, DEILVIN V. VASQUEZ, LIEZEL B.