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Tool Talk Discussion Forum

Machinists help!!

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dr.sportster

11-07-2005 14:25:32




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Im boring an 1 1/4" hole in a freinds Harley crankcase.I have the made in Yugoslavia hobby level boring bar,then the1/2" bar that takes a 1/4"lathe bit everything is tight and centered on the original bored hole,but the bar is chattering bad.I cant shorten it or it wont reach in as far as it needs to go.This guys crankcase is expensive and Im thinking I might have to send this one out as I only have a few thou left before his oversize new breather gear is too loose in the hole.Its sorta a half blind hole so honing is out.Any suggestions appreciated.Thanks.

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Mike M

11-08-2005 10:44:10




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
It's getting way too late in the game to experiment. I was doing some tractor brake drums that were chattering badly. Sprayed some thin aerosol cutting fluid on them and made a big difference. I once read some info on grinding bits they told about the magic chip groove. You gring a deep groove right behind the cutting edge so as to make your cutting edge real steep. I have used these with some success on some things. Since your about out of passes I'd try adding some stuff to dampen like the others mentioned,use cutting fluid,take a super light slow cut and just try to get it to the end.

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Fred OH

11-08-2005 06:12:29




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
I would go about this job different than the others...I would grind up a tool on both ends so that each one cut...the tool is miced and ground till it is the length of the diameter that you want and the setscrew that holds it in is loosly holding it in so that it floats. Then a slow speed and moderate feed will not chatter at all. Old horizontal boring mill secret of many years ago. Fred OH



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Butch(OH)

11-08-2005 05:42:37




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
Never seen a vibration problem that was cured with more speed or feed. Boring can be done with supprizingly flimzy setups and tools if the speed is slow enough. I have bored in my Bridgeprot with a Criterian boring head using 1/2" boring bars sticking out a foot. Just need to slow the spindle down and use the slow feed rate, .0015 per rev I believe?. A good crutch is drill the bar and fill with lead shot. Another is to attach some weights with mentioned rubber bands. Here is a picture of a sleeve boring job I did on my lathe, long bar deep hole. Those sleeves are almost 18" long and 5 1/4" bore just to give you some scale to the picture. The "boring bar' attached to the compand is a 24" legnth of 2 7/16 Stressproof steel with a 1/4" lathe tool attached and doing the work. Chatter could not be controlled even at slowest RPM (25 I think) on my Summit lathe. After drilling a 1" hole in the bar and filling with #9 lead shot chatter was reduced but not cured. Chatter was eliminated with shot and by attaching about 5-6 1" hex nuts around the bar with rubber bands. between these and other ideas your chatter will be gone. Next time find the cure before you get so close to final dimensions, good luck.

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Midwest redneck

11-10-2005 02:06:47




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 Re: Machinists help!! in reply to Butch(OH), 11-08-2005 05:42:37  
Is that a Summit lathe in the picture? That sure looks nice, is it a good machine, I would like to buy one. Is it from Eastern Europe?



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Butch(OH)

11-10-2005 05:23:26




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 Re: Machinists help!! in reply to Midwest redneck, 11-10-2005 02:06:47  
Yes it is a Summit model 16-3 I bought new in 2000. Rated at 16" swing for reasons unknown to me because it swings close to 19" over the ways. Bulgarian made, about twice the money of a Jet and at least three times the machine.



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Butch(OH)

11-08-2005 05:45:03




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 Re: Machinists help!! in reply to Butch(OH), 11-08-2005 05:42:37  
Geez, sorry for all the spellen errors.



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kraigWY

11-08-2005 05:27:35




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
Make a series of larger boring bars, 1 1/2 in hole you can use a fly cutters, less viberation with heavy fly cutters, and they are easy to make too.



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walt sanborn

11-07-2005 16:56:41




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
I think you need to slow down the RPM, witch will also slow down the feed rate, Make sure the centerline of the insert is atleast .010 below the centerline,also get some molding clay and put it around the boring bar, It may sound funny but it takes the viberation out. Lots of luck,Walt



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Davis In SC

11-07-2005 18:31:36




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 Re: Machinists help!! in reply to walt sanborn, 11-07-2005 16:56:41  
Walt, rubber bands help also, I have wrapped them around a boring bar, to help stop vibration. Also , use them wrapped around thinwall pieces I bore in a lathe...



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wow

11-07-2005 16:13:46




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
Without seeing your setup it sounds like your boring bar is too flimsy. You're working in the 9th inning, 2 outs and 2 strikes on the batter if you only have a few thousandths to go- the chatter could easily be that deep. What I'd do is come up with a rigid boring bar (beg, borrow or make) and try it on a scrap piece. It's not hard to indicate your work back into location.



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Midwest redneck

11-07-2005 15:02:39




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
You may want to use a boring bar set that has indexable carbide bits and uses tool steel bars for the shanks, these are somewhat more ridgid and are less prone to chatter, in my opinion.



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Davis In SC

11-07-2005 14:59:28




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 Re: Machinists help!! in reply to dr.sportster, 11-07-2005 14:25:32  
What type of Mill are doing it in??? ... Here are some common causes of chatter when boring: Lack of rigidity in machine,workpiece, set-up, or tool. ... RPM too high, Feedrate too fine, Tool not set on center (Bar canted to front or back) , dull or improperly ground tool... Actually, a very light cut is prone to chatter, because tool is not able to bite in.. Sometimes a slight change in speed, will reduce chatter, it has something to do with the the natural frequencies that things vibrate at...

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dr.sportster

11-08-2005 13:07:56




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 Re: Machinists help!! in reply to Davis In SC, 11-07-2005 14:59:28  
Davis,You had to ask;it is a Bridgeport M head that is adapted to an old horizontal Van Norman table.It sounds wacky but it works really well and it can be disassembled and easily[sorta]moved.Above where I said boring bar I meant Yugoslavian boring head.I think I may have to put a sleeve in this now.I also found out that there is a series of reamers to do the oversize breather but are expensive.Thanks for some good info Gents.

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