Following on from my previous post regarding internal profiling of aluminium, I have got some new tools, and the special geometry ccgt/vcgt inserts. Now the biggest problem I have is the swarf in the hole! I have added a piccy of the part, and you can see the chatter marks on the inside rim. I am using a facing op with a boring bar, high spindle speed, low feed, and 0.4mm depth of cut (Yeah, my little lathe loses too much power at high speed). I tried boring rather than facing first, but the 2' curly swarf was just clogging in the inside and damaging the cutting tip eventually. So, how can I reduce the chips into, well, chips?! I am running out of materials and inserts here, so would like to get it right without another load of practice runs. Any advice would be appreciated.
Oh yeah, I am using flood cooling, would a switch to something else make a difference?
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