by Bernard Martin

Boring bars are indispensable tools for enlarging and refining holes, a critical step in the machining process. They come in various types, each designed to address specific machining needs. Selecting the correct boring bar for use in your your turning application can make your life a lot less stressful. 

During boring operations, the tool encounters forces that can impact its effectiveness. Primarily, tangential and radial cutting forces exert downward and lateral pressure on the tool, potentially causing deflection away from the workpiece.

The Impact of Radial Force
Radial force plays a significant role, especially in scenarios with excessive tool overhang. This force can push the insert away from the cutting surface, leading to deflection and chatter. The extent of this deflection correlates directly with the tool's overhang, depth of cut, and feed rate. Minimizing overhang is crucial to mitigate these issues, ensuring stability and precision. 

Tangential Force Dynamics
Tangential force, on the other hand, tends to displace the tool downward and outward, away from the workpiece's centerline. This displacement can compromise the tool's clearance angle, critical for maintaining the quality of the cut. When boring small diameter holes, maintaining a sufficient clearance angle is paramount to prevent the tool from making unintended contact with the hole's interior walls, preserving the integrity of the bore.

Some Recommendations for Optimal Performance

• Minimize Tool Overhang: Employ the shortest overhang feasible for your operation to reduce the risk of deflection and chatter. Typically you should try to use the largest diameter boring bar possible to maintain rigidity off the boring bar.  We'll dig more into this below.
• Monitor and Adjust Feed Rate and Depth of Cut: Tailoring these parameters can help manage the radial and tangential forces encountered during boring.
• Ensure Adequate Clearance Angle: Especially critical in boring small diameters, a proper clearance angle helps avoid undesirable contact with the workpiece.

​By understanding and addressing the implications of tangential and radial forces, machinists can enhance the accuracy, finish, and overall success of boring operations. These adjustments not only improve tool performance but also extend tool life and enhance workpiece quality.

Selecting the right shank diameter is crucial, and it involves evaluating the minimum machining diameter of the boring bar alongside the desired bore diameter. Optimal selection dictates choosing a shank diameter that is as large as possible.

Nevertheless, it's essential to exercise caution, as a shank diameter that is too close to the bore diameter will lead to chip control at least and chip packing at worst. Consequently, the choice of shank diameter should be tailored to the specific application requirement while leaving enough room for your chips to evacuate.  Remember, if you're roughing you're going to be taking a bigger bite than you are if you are finishing.  

A couple decades ago, I was having some issues with chip packing that I couldn't solve.  I called in my cutting tool specialist, Charles Colerich.  Charles took one look at the application and said "Just turn the bar upside down. Gravity works."  No one ever said the insert needed to be facing upwards. 

​As a result, instead of the chips trying to evacuate over the top of the bar, the coolant washed them under the bar.  Sometimes the best thing to do is step back and look at the problem in its simplest terms and apply some common sense.  When he told the machinist to turn the bar over the shop foreman and I looked at each other and both had  facepalm moment "why didn't; we think of that" together.

Boring bars can be classified based on their material, structure, and construction. The type of boring bar determines the strength of the bar to handle strong cutting forces with minimal vibrations. The most popular boring bars used include steel boring bars, heavy metal bars, carbide bars, and damping bars.

When initially selecting the type of bar you need a good rule of thumb, that is also pretty simple, is 4-6-8-10+.  Take the diameter of your boring bar and multiply it 4.  

​That's about the max depth you should try to bore with a steel bar.  

Here's an easy to remember list of max depth of each type of bar:

• Steel Boring Bars: Up to 4 X Diameter
  
• Heavy Metal Bars: Up to 6 X Diameter
• Carbide Boring bars: Up to 8 X Diameter
• Devibe Boring Bars: Antivibration bars are generally best applied over 10 diameters depth.
  

Everede Tool offers a diverse range of different types of materials on the shanks of their boring bars  The range of tools are notable: From small diameter capabilities, accommodating minimum bore diameters from as small as 0.180" up to sizes exceeding 1.500", depending on the series and specific model. The selection includes options with a 5° positive axial rake, angles designed for facing and through-hole boring, and configurations suitable for boring to the shoulder with 0° angles.

The choice of boring bars in CNC machining is a critical decision that directly influences the quality and efficiency of the machining process. Everede Tools' boring bars stand as a testament to precision engineering, offering a comprehensive range of options with features such as anti-vibration technology, modular design, and high-quality materials. By investing in Everede Tools' boring bars, machinists can elevate their CNC machining capabilities, achieving superior results and staying at the forefront of innovation in the industry.

The team at Browne & Co are excited to invite you to join us at IMTS 2024, which will be held from September 9-14 at McCormick Place in Chicago. This premier event is a vital opportunity to explore the latest advancements in manufacturing technology, network with industry leaders, and discover innovative solutions that can enhance your operations. There will be participation of several of our key principals at the upcoming show.

Dümmel (Booth: 431481)
As part of Everede's booth, Dümmel will be showcasing their exceptional micro-cutting tools, which are ideal for small-part machining and fine-detail work. Dümmel's product range is designed to meet the highest standards of precision and reliability, ensuring optimal performance in intricate machining tasks.

Everede Tool Company (Booth: 431481)
Everede Tool Company will be showcasing their advanced cutting tools, including indexable tools, boring bars, and other precision cutting instruments. Everede is known for producing high-quality tools that provide superior performance and durability. Their products are designed to meet the rigorous demands of modern machining, offering solutions that increase efficiency and precision in manufacturing processes.

Haimer USA (Booth: 431510)
Haimer will be showcasing their industry-leading tool-holding systems, including shrink-fit technology and high-performance balancing machines. These products are known for their ability to improve machining accuracy, reduce vibration, and extend tool life, ultimately boosting overall efficiency in manufacturing environments. Additionally, Haimer's Power Clamp and Tool Dynamic series provide unmatched reliability in tool clamping and balancing, ensuring top-tier production quality.

Nine9 (Booth: 431481)
Also as part of Everede's booth, Nine9 will be exhibiting their innovative cutting tools that are designed to streamline complex machining processes. Highlighted products include the NC Helix Drill, which ramps at 20° angles, enabling the production of multiple features with a single tool, and the i-Center indexable center drill, which offers extreme repeatability and precision.

Precision Brand Products (Booth: 431781)
Precision Brand will display an extensive array of shim products, toolroom supplies, and maintenance tools at their IMTS booth. Their offerings include slotted shim kits, feeler gauge assortments, and stainless-steel shim stock, all of which are critical components in achieving exact measurements and ensuring the longevity of machinery.

IMTS 2024 is the ideal venue to explore these innovative products and speak directly with the experts who design and produce them. We strongly encourage you to add these booths to your IMTS show planner and take advantage of the opportunity to engage with the cutting-edge technologies that can propel your business forward.

For more information and to plan your visit, please visit IMTS 2024​

Let us know if you will be going and we can join you at one of our principals booths!!

Chardon, OH. - Browne & Company, a leader in the metalworking industry, is proud to announce the grand opening of its new Metalworking Technology Center in Northeast Ohio. This state-of-the-art facility is set to revolutionize the metalworking sector with its cutting-edge technology and tooling, provided by the renowned Haimer presetting and shrink fit tooling. 

​You can also find the latest high performance cutting tools displayed from Fullerton Tool, Regal Cutting Tools, Rocky Mountain Twist Drill, The Everede Family of tooling, Dapra, and others. 

The Technology Center is designed to meet the growing demands for higher precision, efficiency, and performance in metalworking. It is equipped with the latest advancements in Haimer technology and tooling, ensuring consistent set-up, unsurpassed machining accuracy, better tool life, and improved part finishes. The center represents a significant investment in innovation and demonstrates Browne & Company's commitment to advancing the metalworking industry.

"We are excited to unveil our new Technology Center, which symbolizes our dedication to providing the best in metalworking solutions," said Dave Browne, President of Browne & Company. "This facility not only showcases the latest in technology and tooling but also serves as a hub for innovation, collaboration, and education."

Schedule a Demonstration
Don't miss the opportunity to experience the latest in metalworking technology and innovation. Click the button below to schedule a demonstration with our team and discover how Browne & Company can elevate your metalworking projects.

About Browne & Company
Browne & Company has been at the forefront of the metalworking industry, offering innovative solutions and high-quality tooling to clients across various sectors. With a focus on precision, efficiency, and reliability, Browne & Company continues to lead the way in metalworking technology and services.

If you're making plans to attend IMTS, be sure and add this group of terrific manufacturers to your your show planner!  Just click on the name, building location or image and you can add them to your "MyShowPlanner"
​

IMTS Booth:  West Building, Level 3 — 431585 — Tooling & Workholding Systems

ARNO FAST CHANGE: Make More Parts Per Shift On Your Swiss Machine
How do you increase spindle up-time on your sliding head Swiss lathe?

1. Reduce tool change times from 7 minutes or more per tool to less than a minute. ARNO’s split shank tool holders allow you to quickly and accurately change tools and get your spindle going again without re-qualifying the zero point.
2. Dismount the tool holder with an easy half turn of the self-releasing wedge clamps. Presently you’re probably spending a lot of time freeing your tool holders from wedge clamps that bind and need coaxed out of position with a mallet or a screw driver. ARNO’s tool change is 100% hassle free so you can get back to dropping parts on the conveyor.
3. Increase tool life with powerful accurate through the tool coolant. The ARNO FAST CHANGE tools can deliver coolant directly to the cutting edge without the need for external coolant lines or spigots that constantly need adjusting.
4. Eliminate bulky high-pressure lines and coolant tubes that occlude your already cramped machining environment. The ARNO FAST CHANGE gang plate is plumbed internally, like a manifold, so there are no external coolant lines. Your machinist will spend less time cleaning dripping oil and chips and more time closing the door and pressing the cycle start button.

ARNO FAST CHANGE… the revolution in Swiss machine productivity

 ​IMTS Booth: West Building, Level 3 — 431452 — Tooling & Workholding Systems

 ​IMTS Booth: West Building, Level 3 — 432234 — Tooling & Workholding Systems

Everede is a Manufacturer of Indexable Boring Bars and Inserts. 
Catalog includes Steel, Carbide, Carbide Bars andmore 
Exclusive USA representative for Nine9 and Duemmel.
Nine9 manufacturer’s high quality unique indexable Engraving, Spotting...
Duemmel manufacturer’s high quality Indexable carbide cutting tools for micro boring, grooving

HAIMER is a first class German Tool Holder manufacturer. From the basics of face-mill arbors and ER collet chucks, all the way up to High Precision Collet and Shrink Fit Chucks, HAIMER has the tools necessary to satisfy and exceed your machining center needs. Their product line includes the most extensive taper and size offerings from any HSK, CAT, BT, SK, PSC and KM tapers to any inch or metric size available. Their product portfolio, which also holds shrink fit, presetting & balancing machines, 3D-sensors, and cutting tools, addresses the machining process from spindle to part, giving the customer a complete machining solution.

 ​IMTS Booth: West Building, Level 3 — 432280 — Tooling & Workholding Systems

For over 75 years, Precision Brand Products has been the benchmark for toolroom products. Our product line of over 2800 products, including shim stock, feeler gauges, key stock, hose clamps and more, has kept pace with the changes and advances in manufacturing technology and methods worldwide.

"Ergo" is a new trademark of Nine9 for ER type indexable cutter. The cutter is assembly kit by the 3 parts including Ergo nut, high strength Ergo pin and Integrated ER taper. Patented design mechanism to produce high clamping Forces and high runout accurancy.

It's perfectly suitable for driven tools and spindles with ER interface of CNC turning centers and swiss type automatic lathes such as Star, Citizen, Tsugami, Doosan, Tornos, INDEX, EMAG and so on.

​The Ergo provides types ER11, ER16, ER20, ER25 taper-shank cutter. The ergo tooling include milling cutter, spot drill, chamfering tool, corner rounding, engraving tool, deburring tool, center drill and boring tool.

This year at PMTS, our Booth # 2088 will be featuring Advanced Chemical Solutions, Fullerton Tool Company, and​ Everede Tool Company. 

​Understanding the relationship between cutting tools and metalworking fluids provides us with an advantage you will not find with any other exhibitor, an advantage that you can put to work for you.
 
Friendly members of our team will be ready to answer any questions you might have.
 
To check out Booth 2088 in person, be sure to register for PMTS below!
 
Hope to see you there!

Two of our most popular chamfer mill systems are on sale until July 31, 2021
Please contact us for your closest, authorized Everede distributor

 Swap a competitors boring bar in usable condition and upgrade to an Everede Bar! Will swap unused inserts and replace with Everede superior grades and chip breakers. (Limited Quantities)

• 30% Discount on Everede Bars with out a swap and we will provide an insert to fill the pocket!
•  Applicable Bar Series: A, B, E, F and ANSI. Also, CHM and IND Series tools.
• Everede will include an insert with purchase, or with the CHM holder, a set to load the cutter. Specify material cutting and where applicable the radius upon order. Grades will be based upon application.

o Excludes Oversize shank bars.
o Excludes modifications such as added flats and cut bars
o Excludes non-stock catalog items such as left hand bars or make to order
items

MADE IN USA! Quality With An Economical Advantage
Highest Quality Lowest Prices 

​Use Ordering code: SEP0502

In January of this year we welcomed a new member to our Browne & Co. sales team and with manufacturing companies opening up again, it's about time we introduce you to Jeff Terrace!

Just before joining Browne & Co in January 2019, Jeff worked at Hoffmann Group, a German cutting tool, hand tool, workstation and storage solutions manufacturer.

Jeff has been working as an InovaTool representative since February of 2019 and recently joined Browne & Company at the beginning of 2020 as our Cutting Tool Specialist. Please send Jeff and email or give him a call to introduce yourself or pick his brain about an application question.

This tool will become the most versatile tool in your shop!

You can spot, engrave, groove and chamfer on milling machines and machining centers.

You can also spot and face on CNC lathes!

​Don't miss out on this very limited time promotion.

Pricing good from May 13, 2019 to May 17, 2019.

Nine9 Multi Function Tools can be purchased from authorized Nine9 distributors.
Please call 440-463-3970 for a distributor in your area.