Upcoming Chapters

Metal Removal
Cutting-Tool Materials
Metal Removal Methods
Machinability of Metals
Single Point Machining
Turning Tools and Operations
Turning Methods and Machines
Grooving and Threading
Shaping and Planing
Hole Making Processes
Drills and Drilling Operations
Drilling Methods and Machines
Boring Operations and Machines
Reaming and Tapping

Chapter 10
Boring Operations
& Machines

Multi Point Machining

Milling Cutters and Operations
Milling Methods and Machines
Broaches and Broaching
Saws and Sawing
Abrasive Processes
Grinding Wheels and Operations
Grinding Methods and Machines
Lapping and Honing

George Schneider, Jr. CMfgE

Professor Emeritus
Engineering Technology
Lawrence Technological University
Former Chairman
Detroit Chapter ONE
Society of Manufacturing Engineers
Former President
International Excutive Board
Society of Carbide & Tool Engineers
Lawrence Tech. Univ.: http://
www.ltu.edu
Prentice Hall: http://www.prenhall.com

10.1 Introduction
Boring, also called Internal Turning, is used to increase the inside diameter of a hole.
The original hole is made with a drill, or it may be a cored hole in a casting. Boring
achieves three things:
Sizing: Boring brings
the hole to the proper
size and finish. A drill
or reamer can only be
used if the desired size
is standard or if special
tools are ground. The
boring tool can work to
any diameter and it will
give the required finish
by adjusting speed, feed
and nose radius. Precision holes can be bored FIGURE 10.1: Adjustable boring bar for precision holes.
using micro adjustable (Courtesy: National Acme Co. Div. DeVlieg-Bullard, Inc.)
boring bars (Fig. 10.1)
Straightness: Boring
will straighten the original drilled or cast hole. Drills, especially the longer ones,
may wander off- center and cut at a slight angle because of eccentric forces on
the drill, occasional hard spots in the material, or uneven sharpening of the drill
(see Fig. 8.10). Cored holes in castings are almost never completely straight.
The boring tool being moved straight along the ways with the carriage feed will
correct these errors.
Concentricity: Boring will make the hole concentric with the outside diameter
within the limits of the accuracy of the chuck or holding device. For best
concentricity, the turning of the outside diameter and the boring of the inside
diameter is done in one set-up, that is, without moving the work between
operations. The basics discussed in Chapters 4 and 5, the Turning Chapters, also
apply to boring. However, with boring there are a number of limitations that must
be taken into account in order to reach a high stock removal rate combined with
satisfactory accuracy, surface finish and tool life. Therefore, in this chapter the
limitations that distinguish internal turning from external turning will be discussed
in greater detail. A typical boring operation is shown in Figure 10.2.

2 Tooling & Production/Chapter 10

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Chap. 10: Boring Operations & Machines

w o r k p i e c e , obtained. The sharp cutting edge
which results penetrates the material more easily
in the deflec- but it is also more easily changed or
damaged by edge or other uneven
tions.
The tan- wear.
Edge wear means that the geomgential force
will try to etry of the insert is changed,
force
the resulting in a reduction in the
Therefore, with
tool down- clearance angle.
wards and finish machining it is the required
away from surface finish of the workpiece that
t
h
e determines when the insert must be
c e n t e r l i n e . changed. Generally, the edge wear
Due to the should be between .004 and .012
curving of inches for finishing and between
the internal .012 and .040 inches for rough
FIGURE 10.2: Typical horizontal boring operation. (Courtesy Sandvik hole diam- machining.
Lead Angle:
The lead angle
eter
the
Coromant Co.)
c l e a r a n c e affects the axial and radial directions
angle will also be reduced. Therefore of the cutting forces. A small lead
10.2 Boring Operations
Most of the turning operations that with small diameter holes it is angle produces a large axial cutting
occur with external turning are also to particularly important that the clear- force component while a large lead
be found in boring. With external ance angle of the insert be sufficient angle results in a larger cutting force
turning, the length of the workpiece in order to avoid contact between in the radial direction. The axial
cutting force has a minimal negative
does not affect the tool overhang and the tool and the wall of the hole.
The radial deflection will reduce effect on the operation since the
the size of the tool holder can be chosen
so that it withstands the forces and the cutting depth. In addition to the force is directed along the boring
To avoid vibrations, it is
stresses that arise during the operation. diametrical accuracy being affected, bar.
However, with internal turning, or bor- the chip thickness will change with consequently advantageous to choose
ing, the choice of tool is very much the varying size of the cutting a small lead angle but, since the
restricted by the work pieces hole di- forces. This causes vibration, which lead angle also affects other factors
is transferred from the cutting edge such as the chip thickness and the
ameter and length.
A general rule, which applies to to the tool holder. The stability of direction of the chip flow, a comproall machining, is to minimize the the tool and clamping will be the mise often has to be made.
The main disadvantage of a small
tool overhang in order to obtain the factor that determines the magnitude
best possible stability and thereby of the vibration and whether it is lead angle is that the cutting forces
are distributed over a shorter section
accuracy. With boring the depth of amplified or dampened.
Insert Geometry: The geometry of the cutting edge than with a large
the hole determines the overhang.
The stability is increased when a of the insert has a decisive influence lead angle. Furthermore, the cutting
larger tool diameter is used, but even on the cutting process. A positive edge is exposed to abrupt loading
then the possibilities are limited insert has a positive rake angle. The and unloading when the edge enters
since the space allowed by the inserts edge angle and clearance and leaves the workpiece. Since
diameter of the hole in the angle together will equal less than boring is done in most cases, in a
workpiece must be taken into consid- 90 degrees. A positive rake angle pre-machined hole and is designated
eration for chip evacuation and radial means a lower tangential cutting as light machining, small lead angles
force. However, a positive rake generally do not cause a problem.
movements.
The limitations with regards to angle is obtained at the cost of the Lead angles of 15 degrees or less
stability in boring mean that extra clearance angle or the edge angle. are normally recommended. Howcare must be taken with production If the clearance angle is small there ever, at a lead angle of 15 degrees
planning and preparation. By under- is a risk of abrasion between the the radial cutting force will be
standing how cutting forces are tool and workpiece and the friction virtually double that of the cutting
affected by the tool geometry and can give rise to vibration. In those force with a 0 degree lead angle. A
the cutting data chosen, and also c a s e s
understanding how various types of where the
boring bars and tool clamping will rake angle
large
affect the stability, deflection and is
the
vibration can be kept to a minimum. and
edge angle
is small, a
10.3 Cutting Forces
On engagement, the tangential force s h a r p e r
and the radial cutting force will at- c u t t i n g FIGURE 10.3: Typical indexable insert boring bar with 0 deg lead angle.
is
tempt to push the tool away from the edge
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Chapter 10/Tooling & Production 3

Chap. 10: Boring Operations & Machines

typical indexable insert boring bar
with a 0 degree lead angle is shown
in Figure 10.3.
Nose Radius: The nose radius of
the insert also affects the distribution
of cutting forces. The greater the
nose radius, the greater the radial
and tangential cutting forces, and the
emergence of vibration. However,
this is not the case with radial
cutting forces. The deflection of the
tool in a radial direction is instead
affected by the relationship between
the cutting depth and the size of the
nose radius. If the cutting depth is
smaller than the nose radius, the
radial cutting forces will increase
with increased cutting depth. If the
cutting depth is equal to or greater
than the size of the nose radius, the
radial deflection will be determined
by the lead angle. Therefore, its a
good idea to choose a nose radius
which is somewhat smaller than the
cutting depth. In this way the radial
cutting forces can be kept to a
minimum, while utilizing the advantages of the largest possible nose
radius, leading to a stronger cutting
edge, better surface finish and more
even pressure on the cutting edge.

10.4 Chip Breaking and Evacuation

Obtaining relatively short, spiral
shaped chips is the goal in internal
turning. These are easy to evacuate
and do not place such large stresses on
the cutting edge when chip breaking
occurs. Hard breaking of the chips, i.e.
when short chips are obtained, demands power and can increase vibration in the boring bar. However, this is
preferred over having long chips,
which can make chip evacuation more
difficult. Chip breaking is affected by a
number of factors such as the insert
geometry, nose radius, lead angle, cutting depth, feed and cutting speed.
Generally, reduced feed and/or increased cutting speed results in longer
chips. The shape of the chip breaker
affects the radius of the chip, where
any built-up edge or crater wear can
also act as chip breaker. The direction
in which the chips flow and the way
that they turn in the spiral, is affected
by the lead angle or the combination of
cutting depth and nose radius.
The parameters that affect chip
control also affect the direction and
size of the cutting force. Therefore,
it is necessary to choose a grade and
4 Tooling & Production/Chapter 10

insert geo m e t r y
that,
together with
the selected
machining
parameters,
fulfill the
requirements for
good chip
control. At
the
same FIGURE 10.4: Various sizes and styles of boring bars. (Courtesy Dorian
time,
the Tool)
machine,
boring bar
and
tool
clamping
must provide sufficient stability in order
to resist the
c u t t i n g FIGURE 10.5: Boring bars are often required to reach long distances
forces that into parts to remove stock. (Courtesy Sandvik Coromant Co.)
arise.
During boring operations the chip reach long distances into parts to
flow can be critical, particularly remove stock (see Fig. 10.5).
when deep holes are being ma- Hence, the rigidity of the machining
chined.
The centrifugal force operation is compromised because
presses the chips outwards. With the diameter of the tool is restricted
boring, this means that the chips by the hole size and the need for
remain in the workpiece.
The added clearance to evacuate chips.
remaining chips could get pressed The practical overhang limits for
into the machined surface or get steel boring bars is four times their
jammed and damage the tool. shank diameter.
When the tool
Therefore, as with internal turning, overhang exceeds this limit, the
tools with an internal cutting fluid metal removal rate of the boring
supply are recommended. The chips operation is compromised signifiwill then be flushed out of the hole cantly due to lack of rigidity and the
effectively. Compressed air can be increased possibility of vibration.
used instead of cutting fluid and
Boring Bar Deflection: The size
with trough holes; the chips can be of the boring bars deflection is
blown through the spindle and dependent on the bar material, the
collected in a container.
diameter, the overhang and size of
the radial and tangential cutting
forces. Boring bar deflection can be
10.5 Boring Rigidity
Part geometries can have external turn- calculated, but such calculations are
ing operations as well as internal op- beyond the scope of this book.
Increasing the diameter of the tool
erations. Internal single point turning
is referred to as boring, and can be to create an increased moment of
utilized for either a roughing or finish- inertia can counteract this deflection.
ing operation. Single point boring Choosing a boring bar made of a
tools consist of a round shaft with one material that has a higher coefficient
insert pocket designed to reach into a of elasticity can also counteract
part hole or cavity to remove internal deflection. Since steel has a lower
stock in one or several machine passes. coefficient of elasticity than ceFigure 10.4 shows various sizes and mented carbide. Cemented carbide
styles of boring bars.
boring bars are better for large
The key to productivity in boring overhangs.
operations is the tools rigidity.
Compensating for Deflection:
Boring bars are often required to Even with the best tool clamping,
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Chap. 10: Boring Operations & Machines

some vibration tendency will occur
in boring. Radial deflection affects
the machined diameter. Tangential
deflection means that the insert tip is
moved in a downward direction
away from the centerline. In both
cases the size and direction of the
cutting forces are affected by
changes in the relationship between
the chip thicknesses and insert
geometry.
If the exact size of the deflection
of the insert tip is known in
advance, then the problem can be
avoided. By positioning the insert
tip distance above the centerline, the
insert under the effect of the
tangential force, will take up the
correct position during machining.
In the same way, setting the machine
at a cutting depth that is greater than
the desired cutting depth compensates for the radial deflection. When
cutting begins, the radial cutting
force reduces the cutting depth.
Even if the approximate deflection
can be calculated, 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.
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.
This type of holder is available in
two styles: a rigid (Fig. 10.6a) or
flange mounted bar, or a divided
block (Fig. 10.6b) that clamps when
tightened. 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 a distance

that gives the required overhang. The bar is then fed into
the holder and clamped by
means of a screw connection or
by being held in the turret.
Less efficient are those toolclamping methods where the
screw clamps onto the bar.
This form generally results in
vibration and is not recommended.
Above all, this
method must not be used for
the clamping of cemented carbide bars. Cemented carbide is
more brittle than steel and
cracks will occur as a result of
vibration, which in turn may
result in breakage.

FIGURE 10.8: Adjustable boring head for

single-point boring tools. (Courtesy
Kennametal Inc.)

10.6 Boring Bars

Boring bars are made in a wide

variety of styles as shown in Figure 10.4. Single-point boring
bars (Fig. 10.7) 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 (Fig. 10.8).
More expensive boring bars
are provided with easily adjustable inserts. These bars are
made in standard sizes, with a
range of 1/4 to 1/2 inch on
the diameter. A fine adjustment
is included in increments of
0.001 inch or in some cases
0.0001 inch. They are standard
up to about 6 inches in diameter.
A boring bar with
adjustments is shown in Figure
10.9.
A different style of
adjustable boring bar with two
indexable inserts is shown in
Figure 10.10.
Standard boring bars with
interchangeable heads to permit
various internal operations such as
turning, profiling,
grooving,
and
threading are shown
in Figure 10.11.
(a)
Many times it
may be economical
to order special
bars with two or
more preset diameters, set at the
(b)
proper
distance
FIGURE 10.6: Two proper boring bar clamping methods. apart. These spewww.toolingandproduction.com

FIGURE 10.7: Single-point boring bar.

(Courtesy Morse Cutting Tools)

FIGURE 10.9: Adjustable boring bar with finetuning adjustment. (Courtesy Valenite Inc.)

FIGURE 10.10: Adjustable boring bar with two

indexable inserts. (Courtesy Kennametal Inc.)

FIGURE 10.11: Standard boring bar with

interchangeable heads for various internal
operations such as turning, profiling, grooving,
and threading. (Courtesy Valenite Inc.)

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Chap. 10: Boring Operations & Machines

Other special boring bars,
sometimes
called
boring
heads, are designed with replaceable cartridges. A twin
cutter adjustable boring tool is
shown in Figure 10.13. Various replaceable cartridges for
special boring heads are
shown in Figure 10.14.
Boring Bar Types: Boring
bars are available in steel,
solid carbide, and carbidereinforced steel. The capacity
to resist deflection increases
FIGURE 10.12: Special multi-operation boring
as the coefficient of elasticity
bar. (Courtesy: National Acme Co. Div. Devliegincreases. Since the elasticity
Bullard, Inc.)
coefficient of carbide is three
cial bars cost more and are generally times larger than that of steel,
only used when large quantities carbide bars are preferred for large
make their use economical. Some- overhangs.
The disadvantage of
times this may be the only way to carbide is its poor ability to withhold the required tolerances and stand tensile stresses. For carbideconcentricity. Such a special boring reinforced bars, the carbide sleeves
bar is shown in Figure 10.12.
are pre-stressed to prevent tensile
stresses.
Boring bars can be equipped
with ducts for internal cooling,
which is preferred for internal
turning.
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 due
to chip jamming, are avoided.
Boring Bar Choice:
When
planning production, it is very
important to minimize cutting
FIGURE 10.13: A twin-cutter adjustable boring
forces and to create conditions
head with indexable Trigon inserts. (Courtesy
where the greatest possible staKomet of America, Inc.)
bility 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.
The following recommendations
should be followed in order to
obtain the best possible stability:
Choose the largest possible bar diameter, but at the same time ensure that
FIGURE 10.14: Various indexable
there is enough room for chip evacuareplaceable cartridges used in special
tion.
boring heads. (Courtesy Valenite Inc.)
6 Tooling & Production/Chapter 10

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.
The indexable 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.
Modern boring bars are designed to
take into account the demands that
must apply because the operation is
performed internally and the dimensions of the tool are determined by the
hole depth and the hole diameter.
With a positive rake insert geometry,
less material deformation and low
cutting forces are obtained. The tool
should offer good stability to resist the
cutting forces that arise and also to
reduce deflection and vibration as
much as possible. Due to space
requirements, satisfactory chip control
and good accessibility are also properties of greater importance than with
external turning.

10.7 Boring Machines

Boring operations can be performed on
other than boring machines, such as
lathes, milling machines, and machin-

FIGURE 10.15: A typical boring

operation performed on a lathe; a steady
rest is being used to provide support for
the part being machined. (Courtesy
Sandvik Coromant Co.)
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Chap. 10: Boring Operations & Machines

Column
Ways
Headstock
Spindle
Y

Cross-sliding
column
Column base

Ways
X

Table

Runway

FIGURE 10.18: Principal parts of a floortype horizontal boring machine (HBM).

FIGURE 10.16: Table-type horizontal boring machine (HBM) (Courtesy Summit

Machine Tool Manufacturing Corp.)

10.7.1 Horizontal
Boring
Machines
(HBM)
The HBM is made to
handle medium to very
large-sized parts, but
these parts are usually
somewhat rectangular
in shape, though they
may be asymmetrical or
irregular. The available
cutting tools only limit
the size of cut, the rigidity of the spindle,
and the available horsepower. There are two
types of Horizontal Boring Machines:
Table-type Horizontal
Boring Machines
(HBM)
The
table-type
HBM shown in Figure
FIGURE 10.17: Large part being machined on a table-type 10.16 is built on the
horizontal boring machine. (Courtesy WMW Machinery Co., same principles as the
Inc.)
horizontal-spindle
milling
machines.
ing centers. A typical boring operation The base and column are fastened
performed on a lathe is shown in Fig- together, and the column does not
ure 10.15. A steady rest is being used move. The tables are heavy, ribbed
to provide support for the part being castings which may hold loads up to
20,000 pounds. Figure 10.17 shows
machined.
Boring machines, like most other a large part being machined on a
machine tools, can be classified as table-type horizontal boring machine.
Size of HBM: The basic size of
horizontal or vertical:
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an HBM is the diameter of the

spindle. Table-type machines usually have spindles from 3 to 6
inches diameter.
The larger sizes
will transmit more power and,
equally important, the spindle will
not sag or deflect as much when
using a heavy cutting tool while
extended.
The size is further
specified by the size of the table.
Although each machine has a standard size table, special sizes may be
ordered. The principal parts of the
horizontal boring machine are shown
in Figure 10.18.
Work Holding: Work holding is
with clamps, bolts, or fixtures, the
same as with other machines. Rotary tables allow machining of all
four faces of a rectangular part or
various angle cuts on any shape of
part. Rotary tables up to 72 inches
square or round are used for large
work. If large, rather flat work is to
be machined, an angle plate is used.
The workpiece is bolted or clamped
onto the angle plate so that the flat
face is toward the spindle. Figure
10.19 shows a five-axis ram-style
machining center.
Parts can be
clamped to the table and numerically
(NC or CNC) positioned to perform
a boring operation.
Cutting Tools: Cutting tools are
held in the rotating spindle by a
tapered hole and a drawbar.
To
speed up the process of tool changing, either or both of two things are
done:
The drawbar (which pulls the tapered
tool holder tightly into the spindle
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Chap. 10: Boring Operations & Machines

0.1 to 40 IPM are commonly used.

Floor Type Horizontal

Boring Machine (HBM)
The floor type HBM
(Fig. 10.18) is used for
especially tall or long
workpieces. The standard 72-inch runway can
be made almost any
length required for special jobs. Lengths of 20
feet are in use today.
The height of the column,
which is usually 60 to 72
inches, can be made to
order up to twice this
FIGURE 10.19: Five-axis ram-style
height if the work remachining center. (Courtesy Giddings
quires it. Figure 10.20
and Lewis, LLC)
shows a large floor-type
horizontal boring machine.
HBM Table: The table
hole) can be power operated. Thus, the
is
separate from the bor- FIGURE 10.21: Vertical boring machine (VBM).
holder is pulled tight or ejected very
ing machine though it is, (Courtesy Summit Machine Tool Manufacturing Corp.)
quickly.
Quick-change tooling is used. A of course, fastened to the
basic holder is secured in the spindle. floor. It may be bolted
10.7.2 Vertical Boring
It has a taper into which tools may be to the runway.
Machines (VBM)
The entire column and column
secured by a quarter to half turn of the
A general description of a vertical borlocking collar. Thus, the operator can base move left and right (the X axis) ing machine would be that it is a lathe
change preset tools in 10 to 30 seconds. along special ways on the runway turned on end with the headstock restTool holders and quick-change (Fig. 10.18). The runway must be ing on the floor. This machine is
tool holders in particular will be carefully aligned and leveled when it needed because even the largest engine
is first installed, and then checked at
discussed in the milling chapters.
lathes cannot handle work much over
Speeds and Feeds: Speeds and intervals as the machine is used.
24 inches in diameter. A vertical borHBM Headstock: The headstock
feeds cover a wide range because of
ing machine is shown in Figure 10.21.
the wide variety of cutters that may can be moved accurately up and
Todays VBMs are often listed as
be used on the HBM. Speeds from down the column (the Y axis). The turning and boring machines. If
15 to 1500 RPM and feed rates from 6 to 10 inch diameter spindle rotates facing is added to that name, it
to do the machining. It is moved in
and out (the Z pretty well describes the principal
uses of this machine. Just like any
axis) up to 48
lathe, these machines can make only
inches for boring
cut, drilling, setting round cuts plus facing and contouring cuts.
the depth of millFigure 10.22 shows the general
ing cuts, etc. As
construction
and the motions availin the table-type
able on the VBM. The construction
HBM, the spindle
is the same as that of the doublediameter and table
size specify the housing planer, except that a round
table has been substituted for the
machine size.
long reciprocating table, and the
Cutting Tools:
Cutting tools are toolholders are different since the
VBM does not need clapper boxes.
the same as those
The size of a vertical boring
used on the tablemachine
is the diameter of the
type
machine.
revolving worktable. The doubleWork holding is
housing VBM is most often made
also the same, and
angle plates are fre- with table diameters from 48 inches
to 144 inches. Larger machines
FIGURE 10.20: Large floor-type horizontal boring machine.
quently used.
(Courtesy WMW Machinery Co., Inc.)

8 Tooling & Production/Chapter 10

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Chap. 10: Boring Operations & Machines

Turret head
Swivel ram head

Turret head

Crossrail

Crossrail

Column

Sidehead
Column

Column

Base

Front View

Table

Base

Side View

FIGURE 10.22: General construction, components and

motions of a vertical boring machine (VBM).

have been made for special work. A rather larg e VBM

is shown in Figure 10.23.

10.7.3 Jig Borers

FIGURE 10.23: Large Vertical Boring Machine (Courtesy: WMW

Machinery Co., Inc.)

Jig borers are vertical boring machines with high precision bearings. They are available in various sizes and
used mainly in tool rooms for machining jigs and fixtures.
More versatile numerically controlled machines are now
replacing many jig borers.

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Chapter 10/Tooling & Production 9