lots of good advice. some We tried already and some new.
The biggest mistery of the job was why it worked perfect for the first 30 odd pieces and not all.
We are looking into the material certs to find differences but in the mean time, we will try some of the tricks of the trade learned here.
Does the boring bar have been removed, manipulated, drop on the floor after the first 30 pieces? A trick that I use sometime when all tricks metionned above doesn't work is to take a honing stone and rub it on the corner radius of the insert to dressed the clearance angle a bit. It will round a bit the cutting edge which in some case does miracle with chattering issue.
use the slowest linear speed possible for your insert. make the depth of cut 150% of your insert nose radius.
of course, do not exceed the max. length of the boring bar
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