Overview

This document provides comprehensive technical specifications, models, and accessory details for the MEGA series of high-precision machining toolholders, collets, tapping holders, angle heads, and spindle systems. Designed for high-speed, high-rigidity machining applications, these products are compatible with BIG-PLUS dual contact spindle systems and conventional spindles.

1. Product Types and Applications

• MEGA MICRO CHUCK & NEW BABY CHUCK: Target micro-diameter tools (0.45 mm to 8.05 mm) with speeds up to 35,000 min^-1, ideal for high-speed machining.
• MEGA E CHUCK: Specialized for high-speed endmilling, clamping 3 mm to 12 mm tools, supporting speeds up to 30,000 min^-1.
• MEGA DOUBLE POWER CHUCK: For larger tools (16 mm to 42 mm), featuring coolant-through holes and high rigidity for heavy and finish milling.
• MEGA ER GRIP: High precision ER collet system (1.9 mm to 20 mm clamping range) ensuring stable runout and improved machining accuracy.
• MEGA SYNCHRO TAPPING HOLDER: Designed for rigid tapping with coolant-through flange standard on BDV40 & BDV50 bodies.
• Additional Accessories: FACE MILL ARBOR, ANGLE HEADS, AIR TURBINE SPINDLES, HIGH SPINDLES, Hi-JET HOLDERS, and DYNA TEST equipment.

2. Technical Specifications

• Clamping Ranges: From ultra-small 0.25 mm to large 42 mm diameters, varying by model.
• Maximum Speeds: Up to 35,000 min^-1 for micro chucks; larger holders support 9,000 to 25,000 min^-1.
• Collet and Nut Models: Specific series per chuck type (e.g., MGN for MICRO CHUCK, MEN for MEGA E CHUCK).
• Dimensions & Weights: Detailed lengths, diameters, and weights provided for precise selection.
• Coolant-Through Features: Integrated in many models to enhance cooling and chip evacuation.
• Compatibility: BIG-PLUS tools fit conventional spindles; MEGA ER GRIP requires BIG collets and nuts for accuracy.

3. Standards and Norms

• Conformance to DIN 69871 A/B standards for BIG-PLUS dual contact spindle systems.
• Use of BDV40 and BDV50 shanks with various lengths and diameters.

4. Accessories and Spare Parts

• Available accessories include MEGA WRENCH, adjusting screws, sealing nuts, protective cases, taper cleaners, and collets.
• Spare parts such as MEGA NUT, MEGA ER NUT, and collet sets support maintenance and replacement.

5. Recommendations and Cautions

• Use only BIG-manufactured collets and nuts with MEGA ER GRIP to maintain precision.
• Balance screws are not included with MEGA ER GRIP and must be sourced separately if needed.
• Wrenches and adjusting screws are often sold separately and are essential for proper assembly.

6. Performance Highlights

• High rigidity and precision achieved via flange contacting nuts and dual contact spindle design.
• Wide range of lengths and collet sizes accommodate diverse machining needs from micro to large diameter tools.
• Coolant-through designs improve tool life and machining quality.
• High-speed capabilities up to 35,000 min^-1 enable efficient machining of carbide drills, reamers, and endmills.

7. Tool Holder and Tapping Holder Specifications

• Sizes MGT6, MGT12, MGT20, MGT36 conform to DIN371, DIN376, DIN353, ISO529, ISO2284 standards.
• Tapping range covers metric taps M2 to M36 and pipe threads P1/8 to P1.
• Coolant-through holes enhance internal coolant supply for improved tool life.

8. BIG-PLUS Dual Contact Spindle System

• Compatible with conventional spindles, offering enhanced rigidity and reduced runout via dual taper and flange contact.
• Conforms to DIN 69871 A/B with BDV model variants.

9. Angle Heads and Adapters

• Types include AG90 NBS, AG90 Build-Up, AG90 HMC, and AGU Universal, supporting spindle angles 0°–90°.
• Adjustable cutter direction (0°–360°) and spindle angles with indexing for 90° increments.
• High rigidity versions feature steel housings and reinforced locating pins for heavy machining.
• Exclusive stop blocks required for safe and accurate positioning.

10. Collets and Chuck Systems

• New Baby Chuck and collets (NBC series) provide high precision with minimal runout.
• Morse taper adapters (MT1, MT2) available for compatibility.
• Face mill arbors and milling chucks support various cutter diameters with parallel reduction collets.

11. Air Turbine Spindle Systems

• Enable machining speeds up to 80,000 min^-1 for micro tools down to 1.0 mm diameter.
• Available in side through and center through types; require clean compressed air and exclusive stop blocks.
• Coolant supply through spindle is not recommended; air pressure controls speed.

12. Key Technical Parameters and Recommendations

• Standard fixed length (A) varies by taper size (e.g., 6 mm for 50 taper, 8 mm for 40 taper).
• Drive key grooves and positioning pins adjustable 0°–360° for flexible tool orientation.
• Exclusive stop blocks mandatory for angle heads and air turbine spindles.
• Coolant-through integrated in many holders; air turbine spindles require clean air without coolant contamination.

13. Usage Notes and Cautions

• Do not perform cutter head indexing inside the machine to preserve accuracy.
• Rotation direction varies by angle head type; some rotate opposite to machine spindle.
• Collets and wrenches generally sold separately; ensure compatibility especially for specialized collets.

14. Spindle System Overview

• Spindle speeds range from 15,000 to 80,000 min^-1 depending on model.
• Air pressure requirements below 0.6 MPa with air flow approx. 300 L/min (ANR) at 0.6 MPa.
• Collet diameters range from 0.45 mm to 20 mm depending on type.
• Dual contact design and long nose minimize interference and improve rigidity.
• Standard fixed length (H) is 6 mm; drive key angle adjustable 0°–360°.
• Lubrication via air purge oil mist recommended; neat oil coolant prohibited due to fire risk.

15. Accessories and Safety

• Exclusive stop blocks and locating pins required for safety and precision.
• Wrenches and adjusting screws provided or available optionally.
• Baby Perfect Seal (BPS) recommended for enhanced sealing performance.

16. Standards and Inspection Tools

• Compliance with DIN 69871 (BIG-PLUS) ensures compatibility with conventional machining spindles.
• Precision test bars available for periodic inspection and ATC repeatability measurement.

17. Summary Tables and Data Highlights

Extensive tables detail model numbers, clamping ranges, max speeds, dimensions, and weights. Key highlights include:

• MEGA MICRO CHUCK models support 0.45–6.05 mm clamping at up to 35,000 min^-1.
• MEGA E CHUCK covers 3–12 mm at ~30,000 min^-1.
• MEGA DOUBLE POWER CHUCK supports 16–42 mm diameters at 12,000–25,000 min^-1.
• MEGA ER GRIP covers 1.9–20 mm at up to 35,000 min^-1.

Conclusion

This document is a detailed technical reference for selecting and using MEGA series precision toolholders, tapping holders, angle heads, and spindle systems optimized for BIG-PLUS dual contact tooling. It emphasizes high rigidity, precision, broad size ranges, and accessory compatibility to meet diverse high-speed machining needs. Adherence to recommended parts, accessories, and safety practices is critical to maintain performance and accuracy.