Composite Tooling

Johnson Carbide Products’ (Saginaw, MI) TruLine Tool® family of carbon fiber/epoxy composite boring tools produce significantly better bored holes in terms of accuracy, surface finish, tool life and productivity.

Johnson Carbide Products’ (Saginaw, MI) TruLine Tool® family of carbon fiber/epoxy composite boring tools produce significantly better bored holes in terms of accuracy, surface finish, tool life and productivity. The tools use a fabrication of composite carbon fibers that are epoxied to a stainless steel cover or sleeve that can be final machined with the necessary insert pockets, screw holes and wear pads. By using composite materials, the boring tools are lightweight but have very high strength with density, stiffness, coefficient of friction and damping characteristics that are significantly better than boring tools made from steel or carbide. Combined with polycrystalline diamond (PCD) guide pads and long length-to-diameter ratios for all types of machine spindles, these composite tools offer users boring tools that have: one-eighth the weight of carbide body tools; eight times the dynamic stiffness of carbide; better surface finish; chatter-free machining up to 30,000 rpm; 10 times the dampening of carbide; up to three times the tool life of comparable steel tools; reduced spindle and magazine loads; up to 40 percent increased speeds/feeds; large-diameter machining on BT40 and CAT40 spindles; and improved workpiece tolerance and roundness. The tools can be manufactured as a solid bar or designed with detachable heads for additional flexibility. Tool shanks can be CAT, BT or HSK. Standard solid boring bars from three-eighths to 1 inch in diameter and from 6 inches to 11 inches long are available as well as a variety of boring bar kits that include a complete set of bars. Because of the inherent lightweight characteristics of the tools, larger bores can be produced on machining centers where weight issues related to the automatic tool changer can be eliminated. Also, with the low coefficient of thermal expansion, the tools eliminate the undesirable additional 6 to 8 micron runout that typically occurs on long boring bars (22-26 inches) when they are stored for extended lengths of time.