Design and manufacture of a carbon fiber epoxy rotating boring bar

High speed boring operations of deep holes with steel or tungsten boring bars are often hindered by the chatter vibration of boring bars because of their low dynamic stiffness and natural frequencies. The chatter is a self-excited vibration that occurs in metal cutting if, either the chip width is too large with respect to the dynamic stiffness of the system, which is proportional to the damping and static stiffness of the boring bar, or the rotating speed of the boring bar approaches one of its natural frequencies, which is proportional to the specific stiffness (E/ρg) of the material used. In this study, a rotating boring bar was designed and manufactured with high stiffness pitch-based carbon fiber epoxy composite to meet the requirements of boring at high rotating speed because carbon fiber epoxy composite materials have a much higher specific stiffness and higher damping than conventional boring bar materials. The optimum design parameters for the composite boring bar were experimentally determined with respect to material types and dimensions of the boring bar through vibration tests. The dynamic characteristics of the composite boring bar developed were measured by the boring operation of aluminum engine blocks. From experiments, it was found that the dynamic stiffness of the composite boring bar was about 30% higher than that of the tungsten carbide boring bar. Also, chatter did not occur up to the ratio of length to diameter (l/d) of 10.7, which is about a 30% improvement compared to the tungsten boring bar of l/d of 8.0.