CUTTING DATA TABLES
144Pages

CUTTING DATA TABLES For fine- and rough boring heads of BIG KAISER

BIG KAISER – the key to higher performance Since 1948 BIG KAISER manufactures high performance tooling solutions for the metal cutting industry. The products are developed to meet the highest standards and are fully produced in Switzerland and Japan. As part of the family owned BIG DAISHOWA Group with more than 800 employees, BIG KAISER has corporate headquarters in Switzerland, Germany and the United States. Founded: 1967 Employees: 640 Location: Osaka and Awaji, Japan Production hall: 6 (Tool holders & Cutting tools), Central stock Asia, TechCenter BIG KAISER Germany Founded: 2010...

CONTENTS GENERAL INFORMATION Cutting Data App / Insert Development Important formulas Taper standards Rough boring with rough boring heads SW Fine boring with fine boring heads EWN/EWE Special applications with fine boring heads EWN/EWE CUTTING DATA Drilling Application data for CBN and PCD inserts On the following pages, tables with recommended speeds and feeds are provided. The values in these tables are the result of practical experience and specific tests. They serve as guidelines to help operators use BIG KAISER boring tools efficiently. For tools in the diameter range from 15 to 340 /...

Cutting Data App / Insert Development A Cutting Data App for Smart Phones and Tablets BIG KAISER has developed a smartphone and tablet app to enhance the user-experience when assembling and running cutting tools while providing extremely precise cutting data. This app will help operators fine tune the optimal cutting parameters for their tool assemblies. They can save their tool adjustment history in the app for future reference; this is an essential "piece-of-the-puzzle" for shops joining the smart manufacturing movement. 61 BIG KAISER boring heads, covering diameters from Ø.01575" (Ø 0.4...

Important formulas Conversion table Metric/Inch Length dimensions Feed per min. Cutting speed Cross section of chip Feed mm/rev to Inch/rev = Material removal rate (Boring) Q = A x Vc (cm3/min) Cutting performance (Boring) ap x fn x Vc x kc (kW) 1000 x 60 Specific cutting force kc1.1 hmc Thickness of chip h = fz x sinκ (mm) With an entering angle of 90° the chip thickness is equal to the feed per tooth (fz). Material removal rate (Drilling) Q= Cutting performance (Drilling) Mc x 2 x π x n (kW) 60 x 1000 Feed force (Drilling) Ff = Workpiece material St 37-2 St 50-2 CK 45 40CrMnMo S 8 6...

Taper standards Steep taper shanks DIN 69871 / DV Position of the cutting edge on single cutter tools Centre and flange through coolant y L1 Steep taper shanks JIS B6339/BT Centre and flange through coolant Position of the cutting edge on single cutter tools BIG CAPTO (compatible with ISO 26623-1, polygonal hollow shank taper with face contact) C ØD1 L1 L2 Orientation groove Position of the cutting edge on

Rough boring with rough boring heads SW Rough boring methods Boring head Examples (Insert holders type CC) DVS/STEP Examples (Insert holders type CC) Boring head ØD2 3. VPS Full profile rough boring Heavily offset cutter arrangement in diameter for largest stock removal (up to 40 % of the final diameter), with surprisingly low power requirement. Due to the use of inserts type WC, the boring head functions like an adjustable insert drill for rough boring. Boring head 2. DVS Double offset rough boring Diameter and height offset cutters allow the removal of twice the stock (20% of the final...

Rough boring with rough boring heads SW Full profile rough boring – Application and adjustment instructions Full profile rough boring permits rough boring with large stock allowances (30 mm and more in diameter) in a single operation, with relatively low drive consumption. Adjustment instructions for insert holders type WC: • Mount the insert holders on mark "RSS“. • Set cutting edge 2 to the final bore diameter (D2). • Set cutting edge 1 corresponding to the starting bore diameter, according to the table (column D1). • Both cutting edges must be located at exactly the same height. Use...

Fine boring with fine boring heads EWN/EWE Fine boring methods There are two different methods of precision boring, machining with the fine boring cycle and machining with the reaming cycle. Both methods have advantages: Fine boring cycle (G 76) boring – spindle stop – spindle orientation – displacement – retraction This cycle is used for: • deep bores with long tools • low cutting speeds and low rpm • large boring diameter > 200 mm Ø • problems with tool life and surface quality Reaming cycle (G 85) Forward – backward boring This cycle is used for: • short bores • small diameters • high...

Special applications with fine boring heads EWN/EWE Chamfering and recessing Special insert holders for chamfering 30° and 45° as well as for recessing in stepped bores. Face grooving Ø 14 - Ø 3 040 mm Face groving Ø 14 - 53 mm With EWN/EWE 2-152, series 112 and special tool and insert holder, groove width 2 – 3 mm, groove depth max. 5 mm Holder for grooving insert Tool holder Grooving insert Face grooving Ø 53 - 3 040 mm With EWN/EWE 53, 68. 100, series 310 and EWN/EWE 200, series 318 and with special insert holders, groove width 2.5 – 4 mm, groove depth 2.7 – 4.3 mm Type 2 Groove...

Cutting data Cutting data for indexable insert drills serie 337 3xD and 4xD, Ø 16-30 mm The above cutting data are guide values and apply under normal working conditions when an ample supply of coolant is used. Machining of aluminium: In case of unfavourable chipping, interrupt drilling cycle for chip removal. Max. drilling depth with flood coolant supply: 1xD Cutting data for indexable insert drills serie 336 2xD and 3xD, Ø 31-74 mm The above cutting data are guide values and apply under normal working conditions when an ample supply of coolant is used. Max. drilling depth with flood...