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given to the cutting edge and difficulty of inspection of the resulting surface size form surface roughness these are the reasons why boring is viewed as an area of machining practice in its own right separate from turning with its own tips tricks challenges and body of expertise despite the fact that they are in some ways identical the first boring machine tool was invented by john wilkinson in 1775 1 boring and turning have abrasive counterparts in internal and external cylindrical grinding each process is chosen based on the requirements and parameter values of a particular application machine tools used edit a horizontal boring mill showing the large boring head and the workpiece sitting on the table boring head on morse taper shank a small boring bar is inserted into one of the holes the head can be shifted left or right with fine gradation by a screw adjusting the diameter of the circle that the cutting tip swings through thus controlling the hole size even down to within 10 micrometres if all machining conditions are good the boring process can be executed on various machine tools including 1 general purpose or universal machines such as lathes turning centers or milling machines machining centers and 2 machines designed to specialize in boring as a primary function such as jig borers and boring machines or boring mills which include vertical boring mills workpiece rotates around a vertical axis while boring bar head moves linearly essentially a vertical lathe and horizontal boring mills workpiece sits on a table while the boring bar rotates around a horizontal axis essentially a specialized horizontal milling machine boring mills and milling machines edit the dimensions between the piece and the tool bit can be changed about two axes to cut both vertically and horizontally into the internal surface the cutting tool is usually single point made of m2 and m3 high speed steel or p10 and p01 carbide a tapered hole can be made by simultaneously feeding the cutting edge in both the radial and axial directions boring machines come in a large variety of sizes and styles boring operations on small workpieces can be carried out on a lathe while larger workpieces are machined on boring mills workpieces are commonly 1 to 4 metres 3 ft 3 in to 13 ft 1 in in diameter but can be as large as 20 m 66 ft power requirements can be as much as 200 horsepower 150 kw cooling of the bores is done through a hollow passageway through the boring bar where coolant can flow freely tungsten alloy disks are sealed in the bar to counteract vibration and chatter during boring the control systems can be computer based allowing for automation and increased consistency because boring is meant to decrease the product tolerances on pre existing holes several design considerations apply first large length to bore diameters are not preferred due to cutting tool deflection next through holes are preferred over blind holes holes that do not traverse the thickness of the work piece interrupted internal working surfaces where the cutting tool and surface have discontinuous contact are preferably avoided the boring bar is the protruding arm of the machine that holds the cutting tool s and must be very rigid 2 because of the factors just mentioned deep hole drilling and deep hole boring are inherently challenging areas of practice that demand special tooling and techniques nevertheless technologies have been developed that produce deep holes with impressive accuracy in most cases they involve multiple cutting points diametrically opposed whose deflection forces cancel each other out they also usually involve delivery of cutting fluid pumped under pressure through the tool to orifices near the cutting edges gun drilling and cannon boring are classic examples first developed to make the barrels of firearms and artillery these machining techniques find wide use today for manufacturing in many industries various fixed cycles for boring are available in cnc controls these are preprogrammed subroutines that move the tool through successive passes of cut retract advance cut again retract again return to the initial position and so on these are called using g codes such as g76 g85 g86 g87 g88 g89 and also by other less common codes specific to particular control builders or machine tool builders lathes edit lathe boring 3 is a cutting operation that uses a single point cutting tool or a boring head to produce conical or cylindrical surfaces by enlarging an existing opening in a workpiece for nontapered holes the cutting tool moves parallel to the axis of rotation for tapered holes the cutting tool moves at an angle to the axis of rotation geometries ranging from simple to extremely complex in a variety of diameters can be produced using boring applications boring is one of the most basic lathe operations next to turning and drilling lathe boring usually requires that the workpiece be held in the chuck and rotated as the workpiece is rotated a boring bar with an insert attached to the tip of the bar is fed into an existing hole when the cutting tool engages the workpiece a chip is formed depending on the type of tool used the material and the feed rate the chip may be continuous or segmented the surface produced is called a bore the geometry produced by lathe boring is usually of two types straight holes and tapered holes several diameters can also be added to each shape hole if required to produce a taper the tool may be fed at an angle to the axis of rotation or both feed and axial motions may be concurrent straight holes and counterbores are produced by moving the tool parallel to the axis of workpiece rotation the four most commonly used workholding devices are the three jaw chuck the four jaw chuck the collet and the faceplate the three jaw chuck is used to hold round or hex workpieces because the work is automatically centered on these chucks the runout faces limitations on late model cncs it can be quite low if all conditions are excellent but traditionally it is usually at least 001 003 in 0 025 0 075 mm the four jaw chuck is used either to hold irregular shapes or to hold round or hex to extremely low runout with time spent indicating and clamping each piece in both cases because of its independent action on each jaw the face plate is also used for irregular shapes collets combine self centering chucking with low runout but they involve higher costs limitations edit for most lathe boring applications tolerances greater than 0 010 in 0 25 mm are easily held tolerances from there down to 0 005 in 0 13 mm are usually held without especial difficulty or expense even in deep holes tolerances between 0 004 in 0 10 mm and 0 001 in 0 025 mm are where the challenge begins rising in deep holes with tolerances this tight the limiting factor is just as often the geometric constraint as the size constraint in other words it may be easy to hold the diameter within 002 at any diametrical measurement point but difficult to hold the cylindricity of the hole to within a zone delimited by the 002 constraint across more than 5 diameters of hole depth depth measured in terms of diameter depth aspect ratio for highest precision applications tolerances can generally be held within 0 0005 in 0 013 mm only for shallow holes in some cases tolerances as tight as 0 0001 in 0 0038 mm can be held in shallow holes but it is expensive with 100 inspection and loss of nonconforming parts adding to the cost grinding honing and lapping are the recourse for when the limits of boring repeatability and accuracy have been met surface finish roughness in boring may range from 8 to 250 microinches with a typical range between 32 and 125 microinches sometimes a part may require higher accuracy of form and size than can be provided by boring for example even in optimized boring the amount that the diameter varies on different portions of the bore is seldom less than 3 micrometre 0001 inches a tenth and it may easily be 5 to 20 micrometre 0002 0008 inches 2 to 8 tenths taper roundness error and cylindricity error of such a hole although they would be considered negligible in most other parts may be unacceptable for a few applications for such parts internal cylindrical grinding is a typical follow up operation often a part will be roughed and semifinished in the machining operation then heat treated and finally finished by internal cylindrical grinding the limitations of boring in terms of its geometric accuracy form position and the hardness of the workpiece have been shrinking in recent decades as machining technology continues to advance for example new grades of carbide and ceramic cutting inserts have increased the accuracy and surface quality that can be achieved without grinding and have increased the range of workpiece hardness values that are workable however working to tolerances of only a few micrometres a few tenths forces the manufacturing process to rationally confront and compensate for the fact that no actual workpiece is ideally rigid and immobile each time a cut is taken no matter how small or a temperature change of a few hundred degrees takes place no matter how temporary the workpiece or a portion of it is likely to spring into a new shape even if the movement is extremely small in some cases a movement of a fraction of a micrometre in one area is amplified in lever fashion to create a positional error of several micrometres for a feature of the workpiece several decimetres away it is factors such as these that sometimes preclude finishing by boring and turning as opposed to internal and external cylindrical grinding at the extreme no perfection of machining or grinding may be enough when despite the part being within tolerance when it is made it warps out of tolerance in following days or months when engineers are confronted with such a case it drives the quest to find other workpiece materials or alternate designs that avoid relying so heavily on the immobility of part features on the micro or nano scales see also edit drilling laser drilling horizontal boring machine jig borer single pass bore finishing references edit pictorial history of england being a history of the people as well as a history of the kingdom volume 1 by george lillie craik charles macfarlane kalpakjian 2001 todd allen 1994 bibliography edit kalpakjian schmid 2001 manufacturing engineering and technology upper saddle river nj usa prentice hall todd robert h allen dell k 1994 manufacturing processes reference guide new york ny usa industrial press v t e metalworking v t e casting processes centrifugal continuous die evaporative pattern full mold lost foam investment lost wax permanent mold plaster mold sand semi solid metal shaw process shell molding spin components chill cope and drag core flask molding sand pattern riser sprue terminology casting defects draft dross foundry ingot semi finished casting products slag v t e forming fabrication and finishing general fabrication piece work sheet metal forming processes coining casting metalworking drawing electrohydraulic forming electromagnetic forming explosive forming extrusion forging hydroforming stamping press hardening progressive stamping punching rolling sinking spinning swaging tube bending joining processes brazing crimping riveting soldering welding finishing processes anodizing galvanizing heat treating mass finishing patination peening plating polishing v t e machining and computing computer aided engineering 2 5d cad cam g code numerical control nc and cnc stewart platform drilling and threading die head drill drill bit drill bit shank drill bit sizes drilling list of drill and tap sizes tap and die tap wrench threading grinding and lapping abrasive abrasive machining angle grinder bench grinder coated abrasive cylindrical grinder diamond plate flick grinder grinding grinding dresser grinding machine grinding wheel jig grinder lapping sanding sharpening stone spark testing surface grinder tool and cutter grinder machining boring broaching electrical discharge machining electrochemical machining electron beam machining end mill engraving facing hobbing jig borer machine tool machining metal lathe milling milling cutter pantograph photochemical machining planer reamer rotary transfer machine shaper skiving turning ultrasonic machining machine tools angle plate chuck collet fixture indexing head jig lathe center machine taper magnetic switchable device mandrel rotary table wiggler terminology cutting fluid machining vibrations speeds and feeds swarf tolerance tool and die making tramp oil workpiece v t e smithing smiths blacksmith bladesmith coppersmith goldsmith gunsmith locksmith pewtersmith sheet metal worker silversmith tinker tinsmith whitesmith processes forging pattern welding planishing raising sinking swaging tools anvil forge fuller hammer hardy tool power hammer pritchel steam hammer swage block trip hammer v t e metalworking tools cutting machines bandsaw cold saw laser miter saw plasma water jet cutter cutting tools broach burr chisel counterbore countersink end mill file hand scraper milling cutter nibbler oxy fuel cutting torch reamer shears tipped tool tool bit forming tools brake die english wheel hydraulic press machine press punch press screw press stamping press hand tools clamp combination square drift pin hacksaw hammer hand scraper hand seamer machinist square needlegun scaler piercing saw pliers punch scriber tap and die tongs vise workbench wrench machine tooling angle plate chuck collet fixture indexing head jig lathe center machine taper magnetic switchable device mandrel rotary table wiggler measuring instruments bore gauge caliper center gauge dial indicator engineer s blue engineer s spirit level feeler gauge gauge gauge block go no go gauge height gauge machinist square marking blue marking gauge marking out micrometer optical comparator radius gauge ruler sine bar straightedge surface plate tape measure thread pitch gauge vernier scale smithing tools anvil forge fuller hardy tools pritchel steam hammer swage block trip hammer v t e welding arc welding atomic hydrogen athydo ahw electrogas egw flash flux cored fcaw gas metal microwire mig gmaw gas tungsten heliarc tig gtaw plasma paw shielded metal stick mma smaw submerged saw other processes electric resistance erw electron beam ebw electroslag esw exothermic forge friction friction stir fsw friction stud laser beam lbw laser hybrid magnetic pulse oxyacetylene oaw spot rsw ultrasonic upset equipment electrode filler metal helmet power supply robot shielding gas related terms heat affected zone photokeratitis residual stress weldability casting fabrication forming jewellery machining metallurgy smithing tools and terminology welding authority control databases national japan retrieved from https en wikipedia org w index php title boring_ manufacturing oldid 1363595204 categories hole making machining hidden categories articles 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