Uncontrolled vibrations have resulted in the demise of many an expensive workpiece and reduced efficiency for the machine operator. But long tool overhangs are often essential during turning, counterboring or threading so what is the answer? "Depending on the material to be machined, these conditions inevitably lead to vibrations that are eventually transferred to the workpiece, with catastrophic effects on the surface quality," explains Christoph Retter, Product Manager at Team Cutting Tools from the CERATIZIT Group. "And, these are not the only limitations for an efficient machining process – accelerated wear through to tool breakage is also a factor. At CERATIZIT we are counteracting this with a new addition to our range, the combination of vibration-damped boring bars and a flexible exchangeable head system."

Quiet, drill!

Up until now, machine operators have usually reduced vibrations by decreasing process parameters such as cutting depth, cutting speed or feed. "With regards to the highest possible efficiency, this is only a temporary workaround as the cycle time often decides whether an order is profitable or not. The CERATIZIT solution is a newly developed exchangeable head system, which can be used with base holders, but also with special boring bars. These effectively minimise irksome vibrations thanks to the damping system in the tool body," explains Christoph Retter.

The result is, that instead of having to reduce the cutting values, even higher parameters are possible. Machining processes with long tool overhangs can be completed far more quickly with vibration-damped boring bars than with those that are not damped. The damped tools improve the surface quality in particular and extend tool lives, whilst at the same time the tool and the machine spindle are under considerably less strain. "This provides for greater sustainability, as all of the components used last significantly longer. Together with the cost savings achieved from extended tool life, the machine operator can now complete even tricky tasks with an increased sense of calm," says Christoph Retter. Thanks to vibration damping, applications are possible that would not be under normal conditions with minimum cutting parameters.

Variable system for a wealth of options

The basis for optimised machining with the vibration-damped boring bars is the newly developed modular exchangeable head system from CERATIZIT. With a selection of eight different exchangeable heads, it is extremely variable, flexible and versatile, which will save on purchase and warehousing costs. Due to the clever positioning of the coolant nozzle, the exchangeable head system also benefits from highly efficient cooling and improved chip clearance.

Standard versions of the base holders are available from CERATIZIT in 200, 218 and 283 mm lengths and diameters of 25, 32 and 40 mm. "The vibration-damped versions come in 150, 185 and 225 mm lengths," says Christoph Retter. Their strengths include process security, reduced costs per component, optimum chip clearance and improved surfaces – and the full benefits can be seen irrespective of the materials to be machined.

Boring bars: quality not available off the shelf

"These components are without a doubt a highlight from the brand-new exchangeable head system product range for turning. The vibration-damped boring bars bring a sense of peace and calm during machining for both the tool and user, and the best part is that the costs are manageable and machine operators won’t need to reach for a stress ball!" summarises Christoph Retter with a wink.

The vibration-damped boring bars and modular exchangeable head system from CERATIZIT will be available from stock as of 23^rd November 2020.

More information can be found at https://cuttingtools.ceratizit.com/gb/en/boring-bar.