Choosing the best equipment can be difficult when you have many options. The CNC boring bar might be a valuable option for you. By doing more research, you could find new customers and explore new possibilities that you did not think of before. This article will show you what to think about and what to watch out for when buying a CNC boring bar. We will begin by explaining how the modern control systems work and how they fit with the vertical and horizontal boring bars.

CNC (Computer Numerical Control) is a manufacturing process that uses computer programs to control the movement and operation of machine tools. It can perform various tasks such as drilling, milling, turning, and cutting with high precision and accuracy. CNC machining has revolutionized the metal working industry by enabling the production of complex and customized parts, improving efficiency and quality, and reducing waste and costs.

The history of CNC machining can be traced back to the mid-20th century, when engineers began to explore ways to automate machine tool operations. The first steps involved using punched paper tapes to control machine movements. In 1952, the Cincinnati Milacron Hydrotel, the first CNC machine, was introduced. It used a hydraulic system to control the motion of a milling machine. Since then, CNC technology has advanced significantly, incorporating electronic and digital components, such as transistors, microprocessors, and software. CNC machines have also become more versatile and adaptable, supporting a wide range of materials and tools.

The impact of CNC machining on the metal working industry has been profound and positive. The machines have enabled the creation of intricate and precise metal parts that were impossible or difficult to make with conventional methods. They have also increased the productivity and efficiency of metal working, as they can operate faster, more consistently, and with less human intervention. CNC machines have also reduced the waste and costs of metal working, as they can optimize the use of materials and energy, and minimize errors and defects. They have also enhanced the innovation and competitiveness of the metal working industry, as they can support the design and development of new and improved metal products and applications.

The boring bar is a versatile tool that many machine shops use to meet the needs of different markets. By combining this tool with the CNC control systems, they can achieve remarkable results and improve their productivity. This article will explore how the CNC boring bar can benefit your business and why you should consider investing in it.

Horizontal and vertical boring bars are machine tools that use a rotating cutting tool to create cylindrical holes or bores in a workpiece.

CNC technology has enabled the automation and optimization of boring operations, allowing for precise control of the boring bar’s speed, feed, depth, and angle.

CNC boring machines can perform various tasks, such as drilling, milling, turning, and cutting, on different types of materials and workpieces, ranging from small to large, simple to complex, and light to heavy.  They have improved the quality and efficiency of boring operations, as they can produce accurate and consistent bores with tight tolerances, reducing errors and defects, and increasing productivity and profitability.  The machines have also enhanced the innovation and competitiveness of the metal working industry, as they can support the design and development of new and improved metal products and applications, such as turbine casings, gun barrels, and pipes.

The importance of high tolerances being achieved in boring operations is evident in the following aspects:

  1. High tolerances ensure the dimensional accuracy and geometric precision of the bores, which are essential for the proper functioning and performance of the metal parts and components.
  2. High tolerances reduce the need for additional machining or finishing processes, such as grinding or honing, which can save time, money, and resources.
  3. High tolerances increase the reliability and durability of the metal parts and components, as they can withstand higher stresses and loads, and resist wear and tear, corrosion, and fatigue.
  4. High tolerances enhance the aesthetic and functional appeal of the metal parts and components, as they can improve the surface finish, smoothness, and appearance of the bores.

The profitability of the boring bar depends on several factors, such as the type, size, and quality of the boring machine, the material and complexity of the workpiece, the demand and competition in the market, and the operational and maintenance costs of the machine. However, in general, boring bars can be profitable for machine shops that can utilize them efficiently and effectively.

Boring bars can complete difficult functions that are needed in many industries, such as aerospace, automotive, energy, mining, and construction. They can create precise and consistent cylindrical holes or bores in various types of materials and workpieces, ranging from small to large, simple to complex, and light to heavy. The machines can also perform various tasks, such as drilling, milling, turning, and cutting, on the same machine, reducing the need for multiple machines and setups.

Boring bars are in high demand in the metal working industry, as they can support the design and development of new and improved metal products and applications. They can also produce accurate and consistent bores with tight tolerances, which are essential for the proper functioning and performance of the metal parts and components. They can also improve the surface finish, smoothness, and appearance of the bores, enhancing the aesthetic and functional appeal of the metal parts and components.

Therefore, every larger machine shop should invest in a boring bar, as it can increase the productivity and profitability of the shop, as well as the innovation and competitiveness of the industry. However, before investing in a boring bar, machine shops should consider many factors.

The average cost of operating a vertical and horizontal CNC boring bar depends on several factors, such as the machine cost, the tooling cost, the material cost, the labor cost, and the overhead cost.

  1. Machine Cost: This includes the purchase cost, the energy cost, the maintenance cost, and the depreciation cost of the CNC machine. The purchase cost of a CNC boring mill machine can range from $500,000 to $5 million. The energy cost can vary depending on the power consumption and the electricity rate. The maintenance cost can include the expenses for repairs, spare parts, and inspections. The depreciation cost can be calculated by dividing the purchase cost by the expected lifespan of the machine. For example, if a CNC boring mill machine costs $1 million and has a lifespan of 10 years, the depreciation cost per year would be $100,000.
  2. Tooling Cost: This includes the costs of the drill bits, collets, tool holders, coolants, and lubricants used in CNC drilling. The tooling cost can vary depending on the type and quality of the tools, the material being drilled, and the complexity of the operation. For example, drilling harder materials can increase tool wear and require more frequent replacements.
  3. Material Cost: This includes the costs of the workpiece material being drilled. The material cost can vary depending on the type, size, shape, availability, and market price of the material. For example, high-performance materials such as titanium or stainless steel are more expensive than plastics or softer metals.
  4. Labor Cost: This includes the wages of the CNC operators and technicians who are involved in the CNC drilling process. The labor cost can vary depending on the skill level, experience, and location of the workers.
  5. Overhead Cost: This includes the indirect costs that are not directly related to the CNC drilling process, such as rent, utilities, taxes, insurance, and administrative expenses. The overhead cost can vary depending on the size, location, and efficiency of the business.

To calculate the average monthly cost of operating a vertical and horizontal CNC boring bar, you need to consider the understanding mentioned above that every machine shop will be significantly different, and the costs can vary widely depending on the specific parameters of each project.

As for the different size boring bar sizes, the cost can also vary depending on the diameter, length, and material of the boring bar. Generally, larger boring bars are more expensive than smaller ones, and harder materials are more expensive than softer ones. However, the size and material used on the boring bar should also match the requirements of the workpiece and the CNC machine. For example, using a boring bar that is too large or too hard for the workpiece can cause excessive vibrations, noise, and tool wear, which can increase the cost and reduce the quality of the CNC drilling. Therefore, it is important to choose the optimal size and material of the boring bar for each project.

A large boring bar requires a strong and stable concrete foundation to support its weight and operation. The concrete foundation also helps to control the fluids and vibration that are generated during the boring process.

The concrete foundation for a large boring bar is usually constructed by drilling holes into the soil using a bored piling machine. The holes are then filled with reinforced concrete to form bored piles or drilled shafts. The bored piles transfer the load of the boring bar to the soil below or rock strata with sufficient bearing capacity and reduce the settlement of the structure. The bored piles also provide lateral resistance and stability to the boring bar against the horizontal forces and moments that are applied during the boring process.

The concrete foundation also serves as a base for the boring bar’s coolant system, which circulates fluids to cool and lubricate the cutting tool and the workpiece. The fluids also help to remove the chips and debris that are produced during the boring process. The concrete foundation must have proper drainage and containment facilities to prevent the fluids from leaking or spilling into the surrounding environment.

The concrete foundation also acts as a damping device to reduce the vibration and noise that are generated by the boring bar. The vibration and noise can affect the quality and accuracy of the bores, as well as the health and safety of the workers and the nearby residents. The concrete foundation must have adequate thickness and stiffness to absorb and dissipate the vibration and noise energy.

The concrete foundation for a large boring bar can be extremely expensive, depending on the size, depth, and number of bored piles required. The cost of the foundation also depends on the soil type, water table, drilling method, concrete quality, rebar quantity, and labor cost. According to some, the average cost of a bored pile is between $50 and $100 per linear foot, and the average cost of a boring mill machine, which can handle larger and heavier workpieces, can range from roughly $500,000 to $5 million. Therefore, the installation budget for a large boring bar must include the cost of the concrete foundation, as well as the operational and maintenance costs of the machine.

Adding the correct piece of machinery to your process can have a significant impact on your company’s profitability and capabilities. The right machine can improve the quality and efficiency of your products, reduce the waste and costs of your operations, and increase the innovation and competitiveness of your industry. However, choosing the wrong machine can have the opposite effect, leading to poor performance, high maintenance, and low customer satisfaction.  The boring bar is a machine that you may want to consider, but you should weigh the benefits and costs of investing in it, and compare it with other alternatives.

 

Darren Harrington is Vice President Commercial Business Real Estate, M&A Advisor of Creative Business Services/CBS-Global.

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