Design Issues in

Long Rotating Boring

Bars

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.

Damped tooling for long tool reach

Self centering tool coupling

Boring very deep holes

The internal machining of large diameter holes, deep holes and a combination of both
usually needs attention to basic points such as
maximum bar diameter; sufficient chip evacuation; positive insert geometry; 90 degree
entering angle; correct insert shape; small nose radius and sharp cutting edge; close
tolerances and high surface finish .
The cutting unit coupling is a critical link and needs to be
beyond any risk of instability. The front end should also
be characterized by low weight. Stability starts at the
back end, where the boring bar is clamped in the machine.
Cutting unit coupling with radial adjustment

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

Most common - self-induced vibration or chatter.

. tool and work move relative to each other in the plane normal to the cut surface.
. primary chatter, regenerative chatter and chatter due to mode coupling effects.
Whether chatter will be maintained or suppressed depends on
1. the dynamics of the cutting process,
2. the dynamics of the machine tool at the tool point, and
3. the mutual directional orientation of 1 and 2.

Eliminating vibration with damped boring bars

Active control is where chatter suppression is achieved by controlling the machining
parameters which sustain the variation in the cutting forces.
Passive control of chatter is a process by which the system instability could be sustained in
the tooling structure by improving the static and dynamic stiffness.

Consider Passive Damping To Bore Deep Holes

The old bromide, 'an ounce of prevention is worth a pound of cure,' comes into play for
preventing chatter when boring deep holes.
For most deep hole boring operations- 4length to diameter and greater- the enemy is chatter.
There are several techniques known to enhance the dynamic stiffness and stability (chatter
resistance) of long boring tools and allow an increase of overhang - up 14 length to diameter.
Structural design. (use of anisotropic mandrels (bars) with specifically assigned
orientations of the stiffness axes)
Material selection and development. (use of high Young's modulus and/or high
damping materials)
Artificial damping.
Localized additives.

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.

Intelligent use of mode-coupling

The effective stiffness of a boring bar may be increased by means of a mechanism known as
mode-coupling which, briefly is the phenomenon of mutual interchanges of vibrational
energies between two modes of vibration of the bar.

The bar possesses two coupled modes and the

dynamic stability depended on the tool setting
angle relative to the principal modal directions.
A design of boring bar using the principle of
mode-coupling

Energy absorption and dissipation from the system

Coulomb or dry-friction dampers
These are dampers that dissipate energy as friction losses through the relative movement
between each pair of surfaces in contact.
Kennametal De-vibrator first reported in 1963, is one example.

It consists of a set of inertial discs made from a type of heavy tungsten alloy, Kennertium .

Undamped vibration absorber or

Frahms Dynamic Vibration Absorber
Passive dynamic vibration absorbers with an inertial mass or pre-tuned bar. This type of
absorber can only be used when. there is a known and constant forcing frequency and is,
therefore, practically useless in suppressing the unstable chatter type of vibration.

Response curve of the 2-DOF

system.

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.

DESIGN OF CANTILEVER BORING BARS WITH DVA

Combination structure
- proposed by Rivin and Lapin and described by Rivin
- breakthrough in the technology for boring bars, and for cantilever structures in general.
The root segment of the cantilever is made of a material with a relatively high Young's
modulus, while no special attention is paid to its specific density, which can be quite
high.

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
)

Figures (a) and (b) show the effective stiffness

and natural frequency of a combination sintered
tungsten carbide-aluminum structure as a function
of the ratio between the "rigid" and "light"
segments.
Corresponding to the highest natural frequency ,
effective stiffness 15% less than the stiffness of
the solid structure made of the "rigid" material,
while its effective mass is 3.5 times less than for
the solid carbide bar.
The natural frequency is 1.8 times higher than
for the solid carbide bar.
enhanced mass ratio of the absorber

Energy absorption and dissipation from the system

Impact dampers
These refer to the class of dampers in which energy is absorbed through the impacts of one
body with another.
Stabor bar is one example. Any vibration of the bar will be suppressed or reduced through
the mass striking the conical seating of the chamber.

Energy absorption and dissipation from the system

Untuned Viscous dampers
As the name indicates, these dampers can all be modelled by the viscous damping analogue.
The most commonly known damper is the Lanchester damper. Energy is dissipated by way of
the flow of fluid in the clearance between the slug and the hole.

OPTIMIZING BUNG LENGTH

FOR MINIMUM AMPLITUDE AT
RESONANCE
This is the expression for the minimun amplitude at

resonance. Apart from the impressed force

which
is generally maintained constant in the experiment,
the parameters K, and
can be manipulated in the
design stages so that will be minimized still further
by appropriate selections in
(a) the bung length
(b) the bung material
(c) the slug absorber material, and
(d) the clearance between the slug and its surrounding

Energy absorption and dissipation from the system

Tuned Damped vibration absorber

Analogy of PERA boring

bar

The vibration absorber of PERA showing

b) Slug suspended on two rubber rings

BORING BAR DESIGN-Solid bar

frequency response of solid bar,

frequency response of tungsten

-bunged bar without slug

BORING BAR DESIGN-Recessed bar

frequency response of recessed bar

frequency response of optimally tuned

main-slug recessed bar

BORING BAR DESIGN-Steel-bunged bar

frequency response of optimally tuned

main-slug steel-bunged bar

frequency response of optimally tuned

twin-slug steel-bunged bar

BORING BAR DESIGN- Tungsten-bunged bar

frequency response of optimally tuned

main-slug tungsten-bunged bar

frequency response of optimally tuned

twin-slug tungsten-bunged bar

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

HOW DOES IT WORK?

Each tool contains a passive damping device that is dynamically tuned. The tuning
process establishes the tools frequency and then positions the damper so the bars
frequency is constantly out of phase. In the out of phase condition, the dampeners
motion is used to suppress the bars vibration or tendency to chatter. In essence, the
energy in the system is absorbed by the damper and not released by the tool in the form
of chatter.

In the late 60,s Austin tool company (3.8) developed a composite

bor ing bar, where the root segment of the bar was made of tubular
tungsten carbide, while the front section incorporated a damper. This
damper makes use of Coulomb or friction damping. A large mass element
as shown in Figure 3.9, was located in the working end of the tool.
This was spring loaded against a suitable bearing surface and supported
concentrically within a tapered cavity. The cavity in the large mass
contains a small mass which is also spring loaded. The arrangement
produces movements of both elements during severe vibration.
With this method of damping there must always be relative motion
between damping mass elements and the bearing surface to generate
Coulomb friction, which provides the resisting force to dissipate the
vibration energy. This force though small, was reported to operate at
such a high frequency that its damping effect was similar to that of
laying a finger on a vibrating violin string.

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.