Introduction
Machining with a horizontal boring mill is a complex process that involves many factors, resulting in a number of common quality issues. With the right tools, methods and parts, proper attention to detail and process can minimize or eliminate most of these quality issues, resulting in improved efficiency and greater cost savings. This article will discuss the most common quality issues with horizontal boring mill machining and their associated solutions.
Common Quality Issues in Horizontal Boring Mill Machining
1. Poor surface finish: Poor surface finish can be caused by poor chip clearance in the cutting tool, too high a cutting speed, or incorrect machining sequence. Solutions include using higher-grade cutting tools, reducing cutting speeds, and changing the machining sequence.
2. Tool chatter: Tool chatter can be caused by vibrations in the cutting tool, or by the cutting forces overcoming the clamping forces of the toolholder. Solutions include changing the cutting tool, toolholder or cutting speed, or adding a damping material to the cut.
3. Sharp corner breakouts: Corner breakouts are typically caused by incorrect machining paths or incorrect feed rate. Solutions include using a slower feed rate and using a balanced cutting path.
4. Incorrect dimensions: Incorrect dimensions can be caused by incorrect tool design and setup, or incorrect cutting parameters. Solutions include changing the cutting parameters, delaying the tool changeover and/or using a more robust tool design.
5. Excessive tool wear: Excessive tool wear can be caused by incorrect cutting parameters (including cutting speed, feed rate and cutting force) or too long a cutting time. Solutions include changing the cutting parameters, shortening the cutting time and using high-grade cutting tools or tool coatings.
6. Poor tool life: Poor tool life can be caused by poor machine rigidity or incorrect cutting parameters. Solutions include increasing the rigidity of the machine, changing the cutting parameters and using high-grade cutting tools.
7. Troublesome chips: Troublesome chips can be caused by incorrect chip clearance, insufficient lubrication or incorrect cutting parameters. Solutions include changing the cutting parameters, increasing the amount of lubricant and/or using a chip-breaking tool.
Conclusion
The key to successful horizontal boring mill machining is having the right tools and cutting parameters and ensuring proper attention to detail and process. By addressing and correcting the most common quality issues with horizontal boring mill machining, it is possible to achieve improved efficiency and cost savings.
