Product Details

Horizontal Boring Machines

A Comprehensive Guide to Horizontal Boring Machines for Manufacturing

Horizontal boring machines are must-have equipment for many manufacturing facilities and construction companies working on large-scale projects. This guide will provide a detailed overview of horizontal borers, their applications, how they work, tips for maximizing productivity, and the top brands and models available.

Alloy Steel Work Spindle

Hardened & Ground-Diameter (MM)

65

80

100

110

125

150

200

Morse Taper Number                                          

4

 

5

6

6

6

Metric 80

Metric 80

Max. Longitudinal Movement of Working Spindle

410

510

510

510

600

800

1000

Number of Spindle Speeds

9

9

9

9

9

9

9

Range of Spindle Speeds - R.P.M.

20 to 300

20 to 300

15 to 250

15 to 250

15 to 250

15 to 250

15 to 250

Longitudinal Work Spindle Feeds (Steps)

9

9

9

9

9

9

9

No. of Axial  Work Spindle Feeds (Nos.)

 

Nil

Nil

3

3

3

3

3

Work Spindle Feed Range

Nil

Nil

0.25 mm/rev.,  0.125 mm/rev. & 0.075 mm/rev.

Max. Height of the Spindle Axis from Table Surface

800

925

1000

1100

1250

1500

2000

Min. Height of the Spindle Axis from Table Surface

20

25

35

35

35

50

50

Dimensions of the Rotary Table

880x1050

900x1105

1030x1375

1100x1450

1225x1675

1500x2000

2000x2000

Longitudinal Table Traverse

1500

1625

1775

1925

2050

2225

2500

Long. Table Traverse Feeds ( Including one Rapid)

10

10

10

10

15

15

15

Transversal Table Travel Feeds (Including one Rapid)

10

10

10

10

15

15

15

Vertical Head Stock Travel Feeds (Including one Rapid)

4

4

4

4

15

15

15

Rotary Table Automatic Feeds ( Including one Rapid)

10

10

10

10

15

15

15

Max. Cross Movement of the Table

910

1000

1100

1300

1550

2000

2500

Max. Distance Between Stay Bearing and Facing Head

2150

2400

2690

2800

2950

3400

4000

Facing Head Diameter

450

505

555

600

650

700

750

Weight Approximate in Kgs. without Packing

7500

8500

10000

11500

16500

20000

25000

What Are Horizontal Boring Machines Used For?

Horizontal boring mills are large industrial machines used to bore and enlarge horizontal holes in heavy metal workpieces like engine blocks, turbines, barrels, presses, railroad wheels, and more. The workpiece remains stationary on the machine table while the boring head moves along horizontal rails or box ways to cut precision holes up to 25 feet deep and up to 6 feet in diameter in the workpiece.

Horizontal boring provides extreme precision and versatility for machining large components that cannot be positioned vertically. Some key applications include:

  • Boring holes for bearings, bushings, pistons, axles, and precision fits in automotive and aerospace parts.
  • Machining and refurbishing large equipment housings like generator frames and hydraulic cylinders.
  • Boring holes in heavy equipment parts like crawler tracks, sprockets, and wheels.
  • Boring perfect alignment between bolt holes in large metal plates.
  • Machining locomotive wheels and large steel pipe.
  • Boring square or irregular shaped holes.
  • Enlarging and smoothing out rough holes from other processes like plasma or flame cutting.

Different Types of Horizontal Boring Mills

There are a few key configurations and designs of horizontal boring machines:

  1. Table Type Boring Mill - The workpiece is mounted on a table that can move longitudinally parallel to the spindle axis for positioning the cuts. This is the most common design.
  2. Floor Type Boring Mill - Workpiece remains stationary while the horizontal boring spindle travels along the floor-mounted rails. Enables very long and heavy workpieces.
  3. Gantry Type Boring Mill - Boring head moved on gantries above a fixed workpiece for boring very large equipment housings.
  4. Rail Guided Boring Mill - Boring head moves on rails guided alongside the machine table. Enables boring multiple surfaces.
  5. Box-Way Boring Mill - Extremely rigid and precise box-way construction. Ideal for repetitive machining tasks that require tight tolerances.

How Does Horizontal Boring Work?

Horizontal boring machines use a rotating, horizontally-oriented boring bar that extends into the workpiece to cut and enlarge existing holes with extreme precision. Here is an overview of how they work:

  • The boring head contains the rotating boring bar and cutter. It is powered by an electric motor and can be manually or automatically controlled.
  • The boring bar holds the detachable cutting tools and is inserted into the existing hole in the workpiece.
  • Cutting tools gradually remove metal material from the inside of the hole in the radial direction to achieve the desired hole size and finish quality.
  • The boring head is fed slowly into the hole via automated or manual controls.
  • On table-type mills, the workpiece can also be moved longitudinally on precision guide ways.
  • Coolant is pumped over the cutting area to reduce heat and wash away metal chips.
  • Once boring is complete, the head retracts and the workpiece is adjusted for the next operation.

Horizontal boring relies on very rigid construction and precision guide ways to produce perfectly straight, aligned holes. The versatility of the independently controlled boring head allows boring at almost any angle necessary on the workpiece.

Tips for Maximizing Productivity of Horizontal Borers

To get the most out of a horizontal boring machine, here are some tips:

  • Select the right sized machine for the workpiece dimensions and weights. This ensures adequate travels and avoids overworking a small machine.
  • Keep gibs, slides, box-ways, and rails lubricated for smooth operation.
  • Use programmable controls and digital readouts for efficiency and accuracy in production environments.
  • Ensure cutting tools are sharp and correctly selected for the material being machined.
  • Schedule routine maintenance and services to keep the machine in top condition.
  • Train operators properly on the machine capabilities to improve proficiency.
  • Clamp workpieces securely using fixtures and direct clamping to the table.
  • Choose appropriate feed rates and cutting speeds based on tooling, depth of cut, and workpiece hardness.
  • Use coolant and clearing chips frequently to prevent overheating tools.
  • Plan machining operations to minimize required positioning of the workpiece.

Top Horizontal Boring Machine Brands

Top of the leading horizontal boring machine manufacturers below:

  • Karam Boring - Offers an extensive range of heavy-duty horizontal borers in India from small to very large capacities. Robust construction and advanced features for demanding projects.

FAQ

What is a horizontal boring machine used for?

Horizontal boring machines are used to bore large, deep, and extremely precise holes in heavy metal workpieces like engine blocks, wheels, cylinders, and turbines.

 

What are the different types of horizontal boring mills?

Common types include table boring mills, floor mills, gantry mills, rail guided mills, and box-way boring mills. Each offers specific advantages depending on the application.

 

How does horizontal boring work?

It works by a rotating boring bar with detachable cutting tools that gets inserted into the hole to gradually enlarge and smooth it to high tolerances and finishes.

 

What industries use horizontal borers?

Automotive, aerospace, off-highway equipment, die/mold shops, military/defense, locomotive, oil & gas, and other heavy industries manufacturing large metal components.

Investing in a robust, high-quality horizontal boring machine provides manufacturing shops with heavy-duty boring capabilities to handle large workpieces with the precision and efficiency needed for production environments.

This guide covers the key factors to consider when purchasing a horizontal borer. Be sure to evaluate the different types, features, workpiece size capacity, accuracy, power, and overall rigidity required for your boring applications.

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