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Stepped cutting is well-suited for working with larger amounts of material and is particularly effective with gummier materials where chip control can be challenging. It excels in situations involving substantial material removal during rough machining, or when dealing with long, stringy chips.

Think things through and make the most informed decision possible—your workpieces will thank you for it. And to learn more about twin cutting, read our boring tool FAQ , or contact us for more information.

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Yes - this article does a good job of breaking down twin bore / rough boring modes and subtleties; matching the variables with best product physics. Thank you

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Balanced cutting should be your go-to option when producing straight, round holes that are easily finished within tight tolerances. The cutting configuration’s stability allows for moderate depths of cut and deep holes, all while maintaining consistency in dimensions and surface finish. That stability also makes it ideal for high-production work situations.

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Now, picture an order for a run of aerospace components made out of a nickel-based alloy. The alloy is known to work-harden and the component geometries are complex. Step cutting’s accuracy and efficient distribution of cutting forces make it the best choice, even if you can’t finish as quickly. But the client lets you know that, if you deliver ahead of schedule, they’ll come to you first with any future orders.

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In stepped cutting, the insert cutting edges are staggered, both in length and in diameter. The result is effectively two tools in one operation. The first is a longer leading insert holder, which cuts a smaller diameter and takes half the stock per cycle. The second insert is set at the final intended size. This configuration is mostly used for larger stock allowances.

In both cases, you must consider the configuration’s advantages and disadvantages, the product, the deadline and other externalities. And those are just two possibilities. In other cases, you may even start out using balanced cutting, then shift to stepped cutting as the project progresses.

In this configuration, the insert cutting edges are aligned with one another in length and diameter. Radial forces cancel each other out and sends axial cutting forces straight back into the spindle.

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Weigh the answers against one another and make a decision. For example, imagine you’ve received an order for a large run of precision bearing housings. The turnaround is quick—making high speed your top consideration. But there’s a wrinkle: the housings are made out of a stainless steel alloy prone to producing long, stringy chips.

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At times, jobs might call for single-point roughing or interpolation with milling cutters. But both those methods have limitations—which is where twin cutting comes in. Often, especially in the case of industries that use castings or forgings, it’s the ideal avenue. And if you’re using twin cutting for your boring needs, you’ll have to choose between two options: balanced cutting or stepped cutting. Let’s review the pros and cons of each.

Every project presents its own challenges. What works perfectly for boring a run of aerospace components probably wouldn’t be ideal for boring gearbox housings. Shops need to make sure they always use what works best for the job—and that includes their cutting configurations.