Damping system eliminates vibration in deep hole boring
- March 29, 2016
BIG Kaiser's new EWN and EWD Smart Damper are precision boring heads with a damping system that eliminates vibration in deep hole finish boring.
The integral design of these new heads shortens the distance from the damping mechanism to the cutting edge, which is the source of vibration. This produces higher damping effects to the tool assembly to minimize the chatter or vibration, achieving better surface finishes and improved metal removal rates.
“For precision machining of deep bores, it had previously been necessary to program low cutting parameters in order to prevent vibrations, which unnecessarily increases machining time”, says Jack Burley, VP sales & engineering of BIG Kaiser. “The EWN/EWD Smart Damper overcomes this problem, and enables high cutting parameters to be used. This means that extremely short turnaround times can be achieved, which improves productivity by up to a factor of ten.”
Tests the company conducted have shown that deep holes free of vibration can be bored with an excellent surface finish with dramatic time savings. For example, with a projection length of 363 mm (14.3 in.) working with high-carbon steel at a cutting speed of 1,300 sfm, an impressive feed rate of 11.4 ipm was achieved with the EWN41 Smart Damper.
The newest Smart Damper solution is either equipped with the tried-and-true EWN analog boring head series, or the latest digital technology in the EWD series. The EWN heads feature a dial with Ø.0005 in./div setting accuracy (.0001 in. w/ Vernier). The EWD heads have a large digital screen, which clearly shows adjustments to an accuracy of Ø.00005 in., thus helping to minimize operator errors and removing the need for complicated Vernier markings. The digital display can be reset to zero at the push of button and has an auto power off function, while the current position of the cutting edge will be shown automatically again due to direct path measurement when the tool is switched on.
The new Smart Damper is compatible with BIG Kaiser's modular CK/CKB system, which means that the length of tool combinations can be freely selected up to a maximum of ten times the diameter, and are capable of being ran on nearly every major spindle interface. All tools are coolant-through, and thanks to three different insert holders per head size, an extraordinary boring range is possible. For example, the EWN and EWD68 heads can bore a range of Ø68 to 150 mm (2.677-5.906 in.). The EWD heads have a seal rating of IP 69K, the highest possible.