Medfab Manufacturing in Lakeville, MN, completes this medical component in difficult-to-machine tantalum using Ingersoll T-Micro elliptical-shank boring bar. Extra rigidity of the bar permits faster metal removal and improves the as-machined finish. In its first application at this location, boring the ID of a titanium tube with a 4-to-1 aspect ratio, and walls as thin as a fingernail, the T-Micro tool completed the part faster, and with a 8- to 10-µ as-machined finish. With previous tooling every part required 15 minutes of hand polishing to reach surface-quality specs.
There is no tooling cure-all for the problems of machining deep cavities, deep holes, or deep slots. Chip evacuation, lateral forces on long unsupported shanks and the risk of chatter inherent in long-reach machining simply compound the basic challenges of cutting metal. However, machine shops across North America have experience that shows there are good workarounds for common long-reach machining operations — techniques that can improve material removal rates and protect the tools ...
Register for Free Access (Valid Email Required)
Please register to get free access to Workarounds that Work for Long-Reach Machining as well as all of American Machinist's exclusive content.