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BIG KAISER Precision Tooling Inc.
HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3

HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3

Product catalog summary

Overview: This document is a comprehensive catalog of high-performance tooling solutions provided by the BIG DAISHOWA Group. It includes detailed specifications, procedures, and recommendations for various types of tool holders and accessories.

Sections:

Tool Holders: The catalog covers a wide range of tool holders including BCV/CV, BBT/BT, HSK, BIG CAPTO, CK/CKB, and cylindrical shanks. Each type is detailed with specifications and applications.
Boring Tools: This section includes rough and fine boring heads, large diameter boring heads, and indexable inserts. Key specifications such as clamping ranges and maximum RPMs are provided.
Cutting Tools: Various cutting tools are listed with their specifications, including drills, end mills, and chamfer mills.
Tool Holder Accessories: Accessories such as pullstud bolts, high-precision test bars, and ATC alignment tools are detailed. The importance of using high-quality accessories for accuracy is emphasized.
BIG-PLUS Spindle System: This section explains the advantages of the BIG-PLUS spindle system, including improved surface finish, extended tool life, and enhanced machining accuracy. The system's compatibility with existing machines and tool holders is highlighted.
Measuring Instruments: The catalog includes various measuring instruments like presetters, touch probes, and tool offset sensors, essential for precision in machining operations.

Key Recommendations: The document stresses the importance of using genuine BIG DAISHOWA components to ensure accuracy and performance. It also highlights the benefits of the BIG-PLUS system in improving machining operations.

Conclusion: The catalog serves as a detailed guide for selecting and utilizing high-performance tooling solutions, emphasizing the integration of advanced systems like BIG-PLUS for optimal machining results.

MEGA Double Power Chuck Overview:

Clamping Range: Ø.500"-1.500" (Ø12-50mm)
Design: High rigidity for heavy cutting with flange contacting nut and simultaneous taper & flange contact.
Max RPM: 30,000
Features: Exceptional rigidity for heavy-duty machining, secure coolant supply, and a variety of straight collets available.

MEGA Perfect Grip Overview:

Clamping Range: Ø.750"-1.250" (Ø16-32mm)
Features: 100% security against end mill slip or pullout, simple handling with secure clamping, and a non-pullout mechanism.
Coolant: Flood jet-through coolant for effective end milling.

New Baby Chuck Overview:

Clamping Range: Ø.010"-.787" (Ø.25-20mm)
Precision: High-precision collet system with 1 micron accuracy at the nose.
Coolant: Coolant through tools with a perfect seal for high-pressure machining.

New Hi-Power Milling Chuck Overview:

Clamping Range: Ø.500"-1.500" (Ø12-42mm)
Features: High rigidity, stable runout accuracy, and heavy-duty gripping force.
Design: Reliable slit design for high accuracy and slim nut diameter to reduce interference.

Hydraulic Chuck Overview:

Clamping Range: Ø.125"-1.250" (Ø3-32mm)
Features: High precision machining, easy clamping with one wrench, and runout accuracy less than .00012".
Design: Internal structure with increased accuracy and rigidity, suitable for various machining applications.

MEGA Synchro Tapping Holder Overview:

Tapping Range: ANSI: No.0-NPT1", JIS/DIN/ISO: M1-M36
Features: Compensates for synchronization errors, improves thread quality, and reduces thrust loads.
Coolant: Coolant through center capability for all models.

CK Boring System Overview:

Features: Safe structure at high torque, rapid adaptation to special tools, and secure contact using a single wrench.
Applications: Supports various applications from rough to fine boring with a large assortment of boring heads and accessories.

Overview: The document provides a comprehensive overview of various boring and turning systems, focusing on high precision and efficiency in machining operations. It highlights different series and types of tools, their specifications, and unique features designed to enhance performance in specific applications.

Specifications: The document details several series of boring heads, including Series 112, 310, and 318, each designed for specific diameter ranges and machining conditions. The tools are available in various materials and configurations, such as aluminum for reduced weight and integral shanks in CV40, BT40, HSK-A63, and C6.

Procedures and Features: The document outlines the use of digital displays for precise measurements, auto-balance types for improved cutting speeds, and variable tool length adjustments for optimal rigidity. It also describes the SMART DAMPER system, which reduces chatter and enhances surface finish and tool life.

Norms and Standards: The tools are designed to meet high precision standards, with features like IP 69K protection against corrosion and advanced electronic components developed by BIG KAISER.

Recommendations: For best results, the document recommends using the shortest possible tool holder length and highlights the importance of proper tool balancing and electronic measurement systems for accuracy.

Key Data and Graphs: The document includes performance comparisons, such as the SMART DAMPER's ability to outperform competitors by six times in productivity, and detailed specifications for various tool series and types.

Applications: The tools are suitable for a wide range of applications, including fine boring, OD turning, face grooving, and high-speed milling. The document also discusses the use of angle heads for combined operations and air power spindles for micro-machining.

High Spindle System Overview: The High Spindle system is designed to enhance machine spindle life by reducing load through reinforced locating pin assembly and multi-directional coolant supply. It features universal coolant nozzles adjustable for maximum delivery to the cutting edge, and a pinpoint coolant jet for short cutting tools.

Hi-JET Holder Overview: The Hi-JET Holder is optimized for small diameter cutters, offering high spindle speeds up to 10,000 RPM and high coolant pressures up to 284 PSI. It features a non-contact seal design to prevent wear and is easy to maintain with replaceable Merit Sets.

Fullcut Mill Overview: The Fullcut Mill offers sharp cutting edges with high radial and axial rake angles, providing smooth end milling and reduced edge chipping. It supports various milling operations like ramping and helical milling, with excellent surface finish and high rigidity.

Speed Finisher Overview: This tool is designed for high-speed machining of aluminum and cast iron, improving surface finish significantly. It features a slim design for increased rigidity and direct coolant supply to the cutting edge.

C-Cutter Mini Overview: The C-Cutter Mini is a compact chamfer mill with four inserts, allowing ultra-high feed rates and increased spindle speeds. It features a new coating for increased cutting speed and efficiency.

Compact Sensor Series Overview: The Compact Sensor Series includes various models for detecting tool positions and reference points, suitable for both conductive and non-conductive materials. It minimizes machine downtime and ensures high precision.

Measuring Instruments Overview: BIG DAISHOWA provides high-quality test bars and measuring devices like the DYNA TEST and DYNA FORCE, ensuring precision and performance of machine tools through regular inspections.

Overview: The document provides a comprehensive guide on machine spindle systems, focusing on dynamic runout, measuring instruments, tool assembly, and balancing requirements. It emphasizes the importance of spindle accuracy for machine tool longevity and outlines various tools and procedures to maintain and measure this accuracy.

Spindle Accuracy: The spindle is crucial for machine tool performance. Dynamic runout, affected by centrifugal forces, vibrations, and heat, must be monitored to optimize cutting parameters. Regular inspection of runout accuracy is recommended to extend machine life.

Measuring Instruments: The document details various measuring tools, including dial indicators, ATC alignment tools, and ceramic taper gauges. These instruments help ensure spindle and tool alignment, reducing runout and potential damage.

Tool Assembly: The document describes several tool holding devices, such as the TOOL PRO and SPINVARIO systems, which offer flexibility and precision in tool positioning. These systems are designed for easy tool access and secure clamping.

Balancing Requirements: Balancing is critical for high-speed tool holders to prevent vibrations and spindle bearing failure. The document explains the balancing process and standards, highlighting the ISO 16084 standard for rotating tool systems, which focuses on spindle and tool interaction.

Cleaning and Maintenance: Various cleaning tools are outlined, such as the T-Slot Clean and spindle cleaners, which maintain tool and spindle cleanliness, ensuring accurate machining and prolonging tool life.

Taper Standards: The document lists various taper standards, including steep and hollow taper shanks, providing detailed specifications for each type to ensure compatibility and performance.

Conclusion: Maintaining spindle accuracy and proper tool balancing are essential for optimal machine tool performance. The document provides detailed guidance on measuring, aligning, and cleaning tools to achieve these goals.

Overview: This document provides detailed specifications for various models of HSK collet chucks, specifically the MEGA series, designed for high-speed machining applications. The document includes technical specifications, clamping ranges, and accessory information for each model.

Specifications: The document lists multiple models of HSK collet chucks, each with specific dimensions and capabilities. Key parameters include clamping range, maximum RPM, weight, and dimensions such as diameter (Ød, ØD), length (L, L1), and height (H). The models are categorized by size and type, such as MEGA4S, MEGA6S, MEGA8S, etc.

Procedures and Recommendations: The document advises on the use of accessories like collets, nuts, and wrenches, which are essential for the proper functioning of the chucks. It emphasizes the importance of using compatible components to maintain accuracy and performance. The document also notes that the practical spindle speed may be influenced by machine rigidity and tool balance, recommending a gradual increase in speed during operation.

Accessories: Various accessories are mentioned, including collets, MEGA nuts, seal nuts, and wrenches. These are crucial for achieving high accuracy and clamping force. The document specifies that some accessories, like the coolant pipe and adjusting screw, are optional and must be ordered separately.

Key Models and Features: - HSK-A40-MEGA4S-60: Clamping range of .018-.159 inches, max RPM of 30,000, weight of .6 lbs.
- HSK-A50-MEGA6S-75: Clamping range of .018-.238 inches, max RPM of 30,000, weight of 1.1 lbs.
- HSK-A63-MEGA8S-90: Clamping range of .116-.317 inches, max RPM of 30,000, weight of 2.0 lbs.

Limitations: The document cautions against using collets and nuts from other manufacturers with BIG’s MEGA ER GRIP chuck bodies, as this may compromise accuracy. It also notes that adjusting screws cannot be used with certain models.

Conclusion: The document serves as a comprehensive guide for selecting and using HSK collet chucks in high-speed machining. It provides essential technical details and recommendations to ensure optimal performance and accuracy.

Overview: The document provides detailed specifications and guidelines for various HSK tool holders and accessories, focusing on smart damper milling, tap holders, modular holders, angle heads, and their respective components. It includes technical specifications, compatibility notes, and accessory requirements.

1. Smart Damper Milling:

Face Mill Arbor Type: Requires separate order for coolant pipe. Includes hook wrench and cutter clamping screw. Damper head is non-removable after use.
Damper Head: Compatible with HSK, BCV, BBT holders. Requires specific mounting methods as per the operation manual.

2. Tap Holders:

Mega Synchro Tapping Holder: Available in various sizes with specific tapping ranges. Requires separate order for coolant pipe, tap holder, and wrench. Rigid tapping function is necessary on the machine tool.
Accessories: Includes tap holder, synchro adjuster, O-ring, screw, and mega wrench.

3. Modular Holders:

CKB Shank: Various catalog numbers with specific dimensions and weights. Coolant pipe is optional.
CKN Shank: Extension and reduction options available. Requires specific accessories for operation.

4. Angle Heads:

AG90 NBS Type: Clamping range from Ø.010" to .787". Requires nut, wrench, and separate order for coolant pipe and collet. Stop block is necessary for mounting.
AG90 Compact Type: Designed for drilling only. Requires stop block and has specific speed ratio and weight specifications.

5. Accessories and Cautions:

Various accessories like collets, wrenches, and stop blocks are mentioned with page references for detailed information.
Cautionary notes include requirements for synchronized tapping functions and limitations on automatic tool changes depending on machine models.

Overview: This document provides detailed specifications and guidelines for various types of HSK collet chucks and hydraulic chucks, designed for high-speed machining applications. It includes information on clamping ranges, maximum RPM, and necessary accessories.

1. HSK Collet Chucks:

MEGA Micro Chuck: Designed for micro drill and end mill applications with a clamping range of Ø.018"-.238". Maximum RPM is 50,000. Accessories such as the MEGA Micro Nut, coolant pipe, collet, and wrench are required separately.
MEGA New Baby Chuck: Suitable for drills, reamers, taps, and finishing end mills with a clamping range of Ø.010"-.787". Maximum RPM is 40,000. Includes a MEGA New Baby Nut, with other accessories sold separately.

2. Hydraulic Chucks:

Ultra Precision Super Slim: Offers a clamping range of Ø.125" with a runout accuracy of 1 micron at 4xD. Maximum RPM is 60,000. Coolant pipe must be ordered separately.
Super Slim: Designed for micro machining with a clamping range of Ø.125". Maximum RPM is 60,000. Coolant pipe and other accessories are required separately.

3. Accessories and Usage Notes:

Accessories such as collets, nuts, wrenches, and coolant pipes are essential for the operation of these chucks and must be ordered separately.
Practical spindle speed may be influenced by machine rigidity and tool balance. It is recommended to gradually increase speed from slow to the desired RPM.
Adjusting screws are not compatible with certain models, and plug screws are recommended for machines not supporting center through coolant.

4. Safety and Best Practices:

Use only cutting tools with a shank tolerance of h6. Avoid using tools with a flat shank or roughing end mills with hydraulic chucks.
Ensure the cutting tool is inserted beyond the minimum clamping length before tightening the clamping screw.

Overview: The document provides detailed specifications and guidelines for various HSK tool holders and accessories, focusing on their dimensions, clamping ranges, and operational recommendations. It includes tables with catalog numbers, dimensions, maximum RPM, and weights for different models.

Specifications: The document lists multiple HSK tool holders, such as MEGA6E, MEGA8E, MEGA10E, and MEGA13E, with specific dimensions (Ød, ØD, ØD1, L, L1, H) and maximum RPMs. It also includes weight information for each model.

Procedures and Recommendations: - Practical spindle speed is influenced by machine rigidity and tool balance. Users are advised to ramp up speeds slowly.
- Adjusting screws are not compatible with certain models.
- For machines not recommending center through coolant, a plug screw should be used.
- Wrenches must be ordered separately.

Accessories: The document references various accessories such as collets, mega nuts, perfect seals, and mega wrenches, with page numbers for further details.

Tables and Data: The tables provide detailed measurements and specifications for each tool holder model, including clamping ranges and maximum RPMs. The tables also specify the necessary accessories and their compatibility with different tool holders.

Critical Information: - Ensure compatibility of tool holders with machine recommendations, especially regarding coolant systems.
- Follow guidelines for tool insertion and clamping to avoid damage.
- Use only specified cutting tools with appropriate shank tolerances.

Overview: This document provides detailed specifications and components for various types of adapters, collets, and accessories used in machining and tooling applications. It includes information on double clamp type adapters, screw-on type turning adapters, carbide shims, and various collet systems.

Adapters:

Double Clamp Type: Designed for negative inserts, includes carbide shim for DN1506 with a thickness of 6.35mm. For DN1504 inserts, a separate carbide shim (DNS1504C) is required.
Cartridge-Turning Adapters: Screw-on type for positive inserts. Wrenches and screws for the carbide seat are included, but the wrench for tightening the clamp piece and inserts must be ordered separately.

Carbide Shim Sets:

Includes various catalog numbers for different insert types and sizes, with specifications for screw and Torx sizes.
Carbide shims are essential for ensuring proper fit and function of inserts in tooling applications.

Clamp Sets:

Details on clamp pieces, screws, and springs for different insert types.
Specific models are marked for exclusive use with certain adapters.

Accessories:

Clamp Screw Set: Includes M3.5 screws and a wrench for VB1604/VC1604 inserts.
Plug Sets: For center-through and side-through applications, with various plug sizes and specifications for different holder types.

Collets:

MEGA Micro Collet: Available in .004" increments for high precision and clamping force.
New Baby Collet: Known for unmatched accuracy, offering runout accuracy of .00004" T.I.R. at the collet nose.

Nuts and Cleaners:

MEGA Micro Coolant Nut: Enhances coolant supply for micro cutting tools, increasing tool lifetime by up to 35%.
Taper Cleaner: Removes particles and oil from chuck bore taper, maintaining precision.

Conclusion: The document provides comprehensive details on the components and accessories necessary for precision machining, emphasizing the importance of using the correct shims, clamps, and collets to ensure optimal performance and accuracy in tooling applications.

Overview: The document provides detailed specifications and guidelines for various collet models used in tool holding applications. It includes information on clamping ranges, dimensions, and compatibility with different tool holders.

Specifications: The document lists multiple collet models such as NBC16, NBC20, and NBC25, each with specific clamping ranges. For example, NBC16-5AA has a clamping range of .193-.197 inches. The collets are categorized by their catalog numbers and corresponding clamping diameters.

Procedures and Recommendations: The document emphasizes the importance of using cylindrical cutting tool shanks without flats for optimal performance. It also highlights the collapsibility of collets, which varies by model, and recommends ensuring the cutting tool shank length matches the clamping section of the collet bore.

Standards and Norms: The collets are inspected for accuracy, with a guaranteed maximum runout of .00004 inches at the collet nose. The document specifies that the tolerance of the cutting tool shank must be within h7 for compatibility.

Additional Features: The document mentions the availability of collet sets and cases, designed to protect and maintain the precision of the collets. It also describes the MEGA NEW BABY NUT, which offers high precision and excellent sealing properties.

Key Data from Tables: The tables provide detailed measurements for each collet model, including clamping size ranges and dimensions such as ØA and B. For instance, the MEGA 16N/NBS16 collet has dimensions ØA=1.00 (25.5mm) and B=1.38 (35mm).

Critical Information: The document includes cautionary notes about the compatibility of collets with certain tools and the importance of maintaining specific tolerances for cutting tool shanks. It also specifies the maximum coolant pressure for certain collet models.

O-Ring Replacement and Tool Holder Accessories Overview:

O-Ring Specifications: O-Rings are sold in packages of 2 pieces. They are essential components for maintaining the seal in tool holder systems, particularly in coolant-through applications.

Tool Holder Accessories: The document details various accessories for tool holders, including collets, nuts, and cleaning tools. These accessories are designed to enhance the performance and longevity of tool holders by ensuring proper sealing and precision.

Collet Models and Specifications: The document provides extensive tables listing different collet models, their dimensions, and compatible cutter shank diameters. Collets are available in both inch and metric measurements, catering to a wide range of applications.

Coolant Pressure and Sealing: The MEGA ER and MEGA E Perfect Seal systems are highlighted for their ability to handle coolant pressures up to 1,000 PSI. These systems use a unique design to improve sealing performance, ensuring efficient coolant flow through tools.

Cleaning and Maintenance: To maintain high precision, the document recommends using taper cleaners for ER and MEGA E collet chucks. Regular cleaning helps preserve the accuracy of the collet taper, which is crucial for precision machining.

Replacement Seals: PS Rings and O-Rings are available for replacement to maintain the integrity of the sealing system. The document lists various models and sizes, ensuring compatibility with different tool holder systems.

Usage Recommendations: It is advised to use cutting tool shanks that match the collet bore diameter exactly, with a tolerance within h7, to ensure optimal performance and prevent damage.

Safety and Caution: The document includes cautionary notes on the proper use of collets and seals, emphasizing the importance of replacing damaged components to prevent coolant leaks and maintain system integrity.

Overview: This document provides detailed specifications and guidelines for Series 319 SW back boring and chamfering insert holders, rough boring heads, and related accessories. It includes information on insert holders for different boring head types, cutting data, and troubleshooting tips for rough boring operations.

Insert Holders: The document describes two types of insert holders, short (S) and long (L), designed for full-profile roughing. These holders are compatible with twin cutter rough boring heads, covering diameters from Ø1.732" to 8.307". Each set includes one insert holder and one blank piece. Specific dimensions and catalog numbers for various boring head types (SW32, SW41, SW53, SW68, SW98, SW148) are provided.

Chamfering Insert Holders: These holders are used for front and back chamfering with adjustable angles from 15º to 75º. They are compatible with Series 319 SW41-SW148 roughing heads. The document lists catalog numbers and dimensions for different chamfering angles.

Face Grooving Holders: These holders allow for the creation of grooves in diameters ranging from Ø2.087" to 8.000". The document provides catalog numbers, dimensions, and insert grades for both uncoated and coated options.

Rough Boring Heads: The document details the specifications for rough boring heads, including tool length adjustment and mounting instructions. It covers a range of outer diameters from Ø.630" to 4.724" and provides catalog numbers for various configurations.

Cutting Data and Insert Selection: Recommended inserts and cutting data are provided for different materials, including mild steels, high carbon alloy steels, stainless steels, cast iron, high temp alloys, and non-ferrous materials. The document includes feed rates, depth of cut, and maximum cutting speeds.

Troubleshooting: Common issues such as poor chip control, chatter, vibration, and insert chipping are addressed with potential causes and remedies. Recommendations include adjusting feed rates, reducing speed, and selecting appropriate insert grades.

Guidelines: The document emphasizes the importance of selecting the correct insert radius based on tool length/diameter ratio and depth of cut. It also highlights the need for clearance between the boring bar and rough bore diameter.

Overview: The document provides detailed technical specifications and guidelines for fine boring operations using BIG KAISER boring tools. It includes troubleshooting tips, product specifications, and accessory compatibility for various boring heads.

Specifications: The document outlines specifications for different fine boring heads, including the EWE 2-152E Digital Fine Boring Head and the EWN 2-152E Fine Boring Head. These heads are designed for high-performance boring operations with a range of diameters and resolutions. The heads feature wireless communication capabilities for easy setup and operation.

Procedures and Troubleshooting: The document provides solutions for common issues such as poor tool life, chips not evacuating, and excessive exit burrs. Recommendations include adjusting feed rates, changing insert grades, and optimizing coolant pressure.

Product Range and Compatibility: The document lists various boring heads and their compatible accessories, emphasizing the modular and integral execution of these tools. It highlights the compatibility of accessories across different models, ensuring flexibility in operations.

Revolutionary Features: The EWE fine boring head is noted for its wireless communication with the BIG KAISER app, which aids in determining optimal cutting parameters and maintaining a history of adjustments.

Key Data and Recommendations: The document includes critical data on cutting speeds, insert selection, and tool holder specifications. It advises on maintaining a balance between feed rates and cutting depths to ensure efficient boring operations.

Conclusion: The document serves as a comprehensive guide for selecting and operating fine boring heads, providing essential information for optimizing machining processes and addressing common operational challenges.

Overview: This document provides detailed specifications and guidelines for fine boring heads and inserts used in machining various materials. It includes cutting data, insert selection, and operational recommendations for optimal performance.

Specifications: The document lists various inserts and their corresponding cutting speeds, feed rates, and stock allowances for different materials such as cast iron, high-temperature alloys, copper alloys, aluminum/magnesium, and tool steel. Each material type has specific insert codes and operational parameters to ensure precision and efficiency.

Procedures: Fine boring guidelines emphasize the importance of balancing stock removal, feed rate, and cutting speed to avoid excessive cutting forces and chatter. Recommendations are provided for achieving stable cuts by adjusting the depth of cut (D.O.C.) and feed rate relative to the insert nose radius.

Norms and Recommendations: The document outlines the effects of cutting speed on surface finish, machining time, and tool life. It advises on the optimal length/diameter ratio and insert radius for different boring operations to minimize vibration and chatter.

Tools and Accessories: Detailed descriptions of various fine boring heads, including EWE digital, EWN, and EWB balanced heads, are provided. The document highlights the features of each tool, such as wireless communication capabilities, damping technology, and material composition, to enhance precision and productivity.

Key Data from Tables and Charts: The document includes tables listing insert codes, cutting speeds, and feed rates for different materials. Charts illustrate the relationship between tool length/diameter ratio, insert radius, and speed reduction to guide users in selecting the appropriate tool configuration.

Critical Information: Emphasis is placed on selecting the correct insert and cutting parameters to achieve desired machining outcomes. The document also provides troubleshooting tips and application advice to address common issues encountered during fine boring operations.

Overview: This document provides detailed specifications and guidelines for fine boring operations, focusing on vibration-free finishing in bores with challenging diameter-to-length ratios. It includes information on boring bars, insert holders, and large diameter boring heads, along with troubleshooting advice and cutting data for various materials.

Specifications: The document lists various boring heads and bars, detailing their dimensions, weight, and compatible inserts. It includes catalog and reference numbers for easy identification. The specifications cover different types of materials such as mild steel, high carbon alloy steel, stainless steel, cast iron, high-temperature alloys, copper alloys, and aluminum/magnesium.

Procedures: The document outlines procedures for selecting the appropriate boring tools and inserts based on material type and desired finish. It provides cutting speed and feed rate recommendations, emphasizing the importance of adjusting these parameters under different conditions to optimize tool life and surface finish.

Troubleshooting: Common problems such as poor tool life, chatter, vibration, poor size repeatability, unacceptable roundness, and poor surface finish are addressed. The document suggests remedies like changing insert grades, adjusting speeds, applying coolant, and modifying tool configurations.

Recommendations: For optimal boring performance, the document recommends using rigid fixtures, ensuring good machine spindle conditions, and selecting the correct insert holder size. It also advises on the use of SMART DAMPER technology to reduce vibration in large diameter boring operations.

Cutting Data: Detailed tables provide cutting data for various materials, specifying insert types, stock allowance, feed rates, and speeds. The data is categorized under optimal and critical conditions, with cautionary notes on maximum speeds for specific boring head models.

Accessories and Spare Parts: The document includes a section on available accessories and spare parts, with catalog numbers for ordering. It covers items like extension slides, clamp bases, and insert holders, highlighting their compatibility with different boring head series.

Overview: This document provides detailed specifications and guidelines for large diameter boring tools, focusing on component selection, assembly, and operational procedures. It includes tables for selecting appropriate components based on diameter ranges and provides safety instructions for tool usage.

Specifications: The document outlines the specifications for large diameter boring heads, including the range of diameters they can accommodate (Ø7.87"-118.10"). It details the components required for different diameter ranges, such as extension slides, clamp bases, and insert holders, and specifies the positions for mounting these components.

Component Selection: Tables are provided to assist in selecting the correct components for both rough and fine boring operations. These tables specify the necessary extension slides, boring heads, insert holders, and counterweights for each diameter range. The document also includes catalog and reference numbers for easy identification of parts.

Accessories and Spare Parts: The document lists various accessories and spare parts, including counterweights, coolant pipes, and flange adapters. It provides catalog numbers and reference numbers for ordering these components.

Assembly Instructions: Detailed instructions are provided for assembling the boring tools, including the use of bridges and extension slides. The document specifies the positions for mounting components and provides guidelines for balancing the tool assembly.

Safety Instructions: Safety guidelines are included, emphasizing the importance of adhering to maximum speed limits based on the boring diameter and extension slide used. The document advises on the proper connection of the bridge tool to the machine spindle and provides recommendations for roughing and finishing operations.

Application Notes: The document provides application notes for roughing and finishing operations, specifying the conditions under which each operation is recommended. It highlights the importance of machine spindle condition and provides guidelines for minimizing vibration during operations.

Specifications and Torque Recommendations: The document provides torque specifications for tightening screws, with recommended torque values listed for various sizes. It includes compatibility details for Torx and Torx Plus systems, and catalog numbers for different tool holders and spare parts.

Tool Holders and Spare Parts: Details on tool holders, spare parts, and compatibility with Torx and Torx Plus systems are provided. The document lists catalog numbers for various screws and wrenches, specifying maximum tightening torque and packaging details.

Lubrication Recommendations: For lubricating fine boring heads, the document recommends using Mobil Vactra Oil No. 2 or BP Energol HLP-32. Lubrication instructions are included with each head.

Cutting Tools Overview: The document outlines various cutting tools, including drills, indexable insert drills, end mills, face mills, chamfer mills, and groove milling tools. It provides specifications for Series 336 and 337 insert drills, including design features, connection types, and application advice.

Drill Specifications: Details on drill sizes, lengths, and connection types are provided for Series 336 and 337 insert drills. The document includes a carbide selection chart for different materials and cutting conditions.

Cutting Data and Requirements: The document provides cutting data, including horsepower and coolant requirements for drilling operations. It specifies cutting speeds, feed rates, and coolant delivery methods for various materials and drill diameters.

Overview: The document provides detailed specifications and guidelines for the Fullcut Mill Type FCM, focusing on indexable end mills with various taper shank adapters and styles, including inch and metric styles. It includes information on accessories, inserts, and cutting tools.

Specifications: The Fullcut Mill is available in different taper shank adapters (40 and 50 taper) and styles (inch and metric). The document lists catalog numbers, dimensions (ØD, ØD1, ap, L, L1, L2), number of inserts, insert models, and weights for various models. The effective cutting edge length (ap) is highlighted as a critical parameter.

Procedures and Recommendations: Inserts must be ordered separately, and the document emphasizes the importance of using the correct insert model for each cutter diameter to avoid compatibility issues. It recommends regularly replacing clamping screws and wrenches to maintain proper clamping force.

Norms and Standards: The document references ASME B5.50-1994 for inch style specifications and MAS 403 for metric style specifications. It also provides guidelines for selecting between ACP200 and ACP300 inserts based on wear resistance and chipping properties.

Limitations and Cautions: The Fullcut Mill Type FCM is not suitable for feeding in the Z-axis, such as ramping, plunging, and boring. It is recommended for use in machines with small spindle tapers due to increased rigidity from reduced gage length.

Accessories and Inserts: The document lists various accessories and inserts, including coolant pipes and clamping screw sets. It specifies that inserts are available in packages of 10 pieces and provides a classification of inserts based on ISO material grades and coatings.

Cutting Data: The document provides cutting data for different work materials, including carbon steel, alloy steel, unalloyed steel, and prehardened steel. It emphasizes the importance of starting with the lowest possible conditions and gradually increasing them while observing the cutting status.

Overview: This document provides detailed specifications and guidelines for the C-Cutter Mini series, which are specialized chamfer mills designed for precision chamfering tasks. The document includes information on various models, their specifications, accessories, and recommended cutting conditions.

Specifications:

Models: The document lists multiple models such as ST10-C0207, ST16-C0515, and others, each with specific dimensions and capabilities.
Chamfer Angles: Chamfering angles range from 5º to 85º, adjustable with a hex key.
Insert Types: Includes standard and sharp edge (SE) types, with specific recommendations for different materials.

Procedures:

Chamfering Range: The document provides a detailed table of chamfering ranges for different angles, specifying the smallest and largest hole diameters and lengths.
Cutting Conditions: Guidelines for cutting speed and feed rates are provided for various materials, including steel, cast iron, and aluminum, with recommendations for wet or dry cutting.

Standards and Recommendations:

Insert Clamping: Wrench and screws are included with the tool, but inserts must be ordered separately. Regular replacement of clamping screws and wrenches is recommended to maintain clamping force.
Material Compatibility: Different insert grades are recommended for specific materials, such as ACP200 for steel and DS20 for aluminum.

Accessories:

Inserts: Various insert models are available, each with specific applications and coating options like PVD and DLC for enhanced performance.
Spare Parts: Includes clamping screw sets and wrenches, with specific models listed for different cutter sizes.

Key Data from Tables:

Cutting Edge Details: Tables provide dimensions for cutting edges, including diameter, length, and offset amounts for different models.
Chamfering Data: Detailed tables outline cutting speeds and feeds for different materials and chamfering modes, emphasizing the importance of adjusting parameters based on machine and workpiece conditions.

Conclusion: The C-Cutter Mini series offers a versatile range of chamfering tools suitable for various materials and applications. Proper selection of inserts and adherence to recommended cutting conditions are crucial for optimal performance and tool longevity.

Overview: This document provides detailed specifications and recommendations for various cutting tools, including chamfer mills, centering cutters, and radius mills. It includes data on cutting speeds, feed rates, and recommended conditions for different materials.

Specifications:

Chamfer Mills: Various models are listed with specifications such as diameter, length, and insert type. Chamfering angles are specified at 90º and 120º.
Centering Cutters: Designed for spot drilling and chamfering, with specifications for different materials like carbon steel, stainless steel, and aluminum.
Radius Mills: Includes models for front and back chamfering with detailed dimensions and insert specifications.

Cutting Conditions:

Recommended cutting speeds and feed rates are provided for different materials, including steel, cast iron, and aluminum.
Specific conditions are advised for wet and dry cutting, with recommendations for using water-soluble cutting fluids to prevent built-up edges.

Inserts and Accessories:

Inserts are available in various grades for different materials, with specific clamping screw sets included.
Accessories such as wrenches and screws are included with the tools, and regular replacement is recommended to maintain performance.

Recommendations:

Adjust cutting conditions based on machine tool and workpiece conditions.
Use water-soluble cutting fluid during spot drilling and dry cutting for traverse chamfering unless severe built-up edge occurs.
Hand feeding is not recommended for these tools.

Operating Instructions and Product Overview:

Coolant Through System: The document provides specifications for coolant systems designed to improve work safety and efficiency by quickly removing heated swarf and preventing thermal displacement. Key benefits include faster table cleaning and improved machining precision.

Accessories: The document lists various T-Slot cleaners available in different sizes to fit machine tables. These cleaners help in quick removal of chips, reducing clean-up time, and maintaining machining precision. The document specifies different catalog numbers, widths, and tolerances for these accessories.

Product Range: BIG DAISHOWA offers a wide range of high-precision tooling systems and solutions for industries such as automotive, military, aerospace, energy, and micro-technology. Their product portfolio includes over 20,000 precision tools adhering to high-quality standards.

Tooling Solutions: The document outlines various tooling solutions offered by BIG DAISHOWA, including boring tools, tool holders, turning tools, cutting tools, tool measuring and management systems, and zero-point workholding systems.

Company Overview: BIG DAISHOWA is a global manufacturer with facilities in Japan, Switzerland, Germany, and the USA. They are recognized for their high standards in precision tooling systems and solutions, aiming to partner with companies requiring extreme accuracy and efficiency.

Catalog excerpts

HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3

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BCV/CV SHANKS TOOL HOLDERS BBT/BT SHANKS HSK SHANKS BIG CAPTO SHANKS CK/CKB SHANKS CYLINDRICAL SHANKS N/C LATHE TOOLING MILLTURN TOOLING TOOL HOLDER ACCESSORIES BORING TOOLS ROUGH BORING HEADS CENTRIC CUTTING EDGE FINE BORING HEADS PERIPHERAL CUTTING EDGE FINE BORING HEADS LARGE DIAMETER BORING HEADS INDEXABLE INSERTS BORING TOOLS SPARE PARTS CUTTING TOOLS ACCESSORIES This Catalog Contains Patents and Trademarks of the BIG DAISHOWA Group Pending and Patented at the U.S. Patent Office

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-4

INDEX COLLET CHUCKS CLAMPING RANGE: Ø.018"-.317" (Ø.45-8.05mm) OVERVIEW X18 COLLET CHUCKS COLLET CHUCKS CLAMPING RANGE: Ø.010"-1.000" (Ø.25-25.4mm) OVERVIEW X19 CLAMPING RANGE: Ø.010"-.787" (Ø.25-20mm) OVERVIEW X24 MEGA MICRO CHUCK MEGA NEW BABY CHUCK COLLET CHUCKS COLLET CHUCKS MILLING CHUCKS CLAMPING RANGE: Ø.075"-.787" (Ø1.9-20mm) OVERVIEW X20 CLAMPING RANGE: Ø.125"-.500" (Ø3-12mm) OVERVIEW X21 MEGA DOUBLE POWER CHUCK MILLING CHUCKS HYDRAULIC CHUCKS MILLING CHUCKS CLAMPING RANGE: Ø.500"-1.500" (Ø16-42mm) OVERVIEW X25 CLAMPING RANGE: Ø.125"-1.250" (Ø3-32mm) OVERVIEW X26 MEGA PERFECT GRIP NEW...

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-5

INDEX BASIC ARBORS BASIC ARBORS BASIC ARBORS SHELL/FACE/END MILL MODULAR HOLDERS ANGLE HEADS MEGA SYNCHRO TAPPING HOLDER ANGLE HEAD SPINDLE SPEEDERS SPINDLE SPEEDERS COOLANT INDUCERS HIGH SPINDLE Hi-JET HOLDER

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-6

INDEX MILLTURN TOOLING TOOL HOLDER ACCESSORIES TOOL HOLDER ACCESSORIES PULLSTUD BOLT OVERVIEW X40 TOOL HOLDER ACCESSORIES CAUTION ! Only use pullstud bolts made by BIG. Accuracy is not guaranteed if poor-quality pullstud bolts are used. TOOL HOLDER ACCESSORIES BIG-PLUS CLEANER OVERVIEW X57 HIGH-PRECISION TEST BAR DYNA TEST ATC ARM POSITIONING TOOL ATC ALIGNMENT TOOL TOOL HOLDER ACCESSORIES FINE BORING ROUGH & FINISH BORING

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-7

INDEX LARGE DIAMETER BORING INDEXABLE INSERTS INDEXABLE INSERT & SPADE DRILLS FACE MILLS FACE MILLS FULLCUT MILL CHAMFER MILLS CHAMFER MILLS CHAMFER MILLS FULLCUT MILL C-CUTTER MINI

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-8

INDEX CHAMFER MILLS RADIUS MILLS BACK SPOT FACING TOOL GROOVE MILLING TOOLS MEASURING INSTRUMENTS MEASURING INSTRUMENTS TOUCH PROBE & EDGE FINDER MEASURING INSTRUMENTS MEASURING INSTRUMENTS MEASURING INSTRUMENTS TOOL OFFSET SENSOR TOUCH PROBE & EDGE FINDER

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-9

INDEX MEASURING INSTRUMENTS MEASURING INSTRUMENTS MEASURING INSTRUMENTS MEASURING DEVICE FOR PULLING FORCE PRECISION MACHINE LEVEL DIAL INDICATOR STANDS TOOL ASSEMBLY DEVICES TOOL ASSEMBLY DEVICES TOOL HOLDING DEVICES TOOL HOLDING DEVICES FLANGE THROUGH COOLANT We offer DIN69871/B flange through coolant upon request. Oil Hole 70 CAUTION ! Tool holders modified for flange through coolant must use proper pullstud to seal backflow of coolant into the spindle.

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-10

BIG-PLUS OVERVIEW BIG-PLUS SIMULTANEOUS TAPER & FLANGE FIT SPACE BIG-PLUS surpasses all other spindle concepts while offering interchangeability with existing machines and tool holders. • Improved surface finish & dimensional accuracy • Extended tool life • Prevention of fretting corrosion caused by heavy cutting • Improvement of ATC repeatability • Elimination of Z-axial movement at high speeds • Improved roundness of boring operations THE BIG-PLUS SPINDLE SYSTEM IS AN ORIGINAL DEVELOPMENT OF BIG DAISHOWA SEIKI CO., LTD. BASIC CONCEPT The BIG-PLUS Spindle System is based on the most current...

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-11

BIG-PLUS OVERVIEW IMPROVEMENT OF ATC REPEATABILITY The BIG-PLUS Spindle System ensures the highest precision location of the tool holder in the spindle when using the ATC for loading tools as a result of the dual contact, which precisely positions the tool holder within 1 micron. ATC REPEATABILITY Machine: Horizontal (4 years old) Taper Contact (Conventional) Dual Contact (BIG-PLUS) Test Bar (Zero Runout) MINIMIZED DEFLECTION FOR MAXIMUM MACHINING ACCURACY & SUPERIOR FINISH With BIG-PLUS simultaneous contact, machining rigidity is greatly enhanced due to the larger contact diameter of the tool...

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-12

HSK TOOLING SYSTEM ISO 12164/DIN 69893/ASME B5.62 Selected materials and strict control of dimensional accuracy for the optimum quality. Wide range of standard holders to meet all production requirements. AVAILABLE IN PREMIUM MATERIAL SELECTION Since HSK is a hollow taper shank, the material has a critical role for optimum performance. BIG uses carefully selected high-grade alloy steels. Particularly, BIG uses die steel materials for HSK40 and smaller where the cross section of shank taper is very thin. HSK Size DRIVE KEY FORM HSK Shanks according to Form A are designed to carry out torque transmission...

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-13

BIG CAPTO ISO 26623-1 A dual contact modular turning and rotating tool holder system that strengthens the performance of MTCs. The BIG CAPTO modular tooling system offers better efficiency, material selection and heat treatment. The trademark CAPTO is licensed from Sandvik Coromant EXCELLENT REPEATABILITY & RUNOUT High repeatability is achieved due to the perfect fit of the polygon taper to drive spindle rotation. The combination of a self-centering 1:20 taper and the long taper edge ensures stable runout accuracy. WIDER RANGE OF ROTATING BIG CAPTO TOOLING THAN ANY OTHER PROVIDER As a licensed...

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-14

CK/CKB/CKN TOOLING SYSTEM OVERVIEW CK, CKB & CKN VARIOUS CONNECTIONS — ONE SYSTEM Based on a cylindrical connection with radial locking screw, the world-famous modular precision tool system by BIG KAISER has continuously been improved over the years, and has adapted to customer’s needs and the increases in machine tool performance. Compatibility to existing tools has always been a requirement for newer designs. This means that all BIG KAISER connections are almost 100% compatible, and all the components are in stock. Recess for the CKB Floating Cross-Bolt CKB CONNECTION: HIGHLY EFFICIENT AND...

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HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 3-15

CK/CKB/CKN TOOLING SYSTEM OVERVIEW CKN CONNECTION: FOR LIGHTWEIGHT AND HIGH PERFORMANCE TOOLS Based on a 3-screw connection and a male pilot with 3 partial slits, the CKN connection is designed for lightweight and high performance tools. The main components for the program are double connector couplings made of steel and extension tubes made of aluminium. The high performance program for enhanced radial stiffness is entirely made of steel components. A-A Double Connector Coupling Connector with Partial Slits Extension Tube Aluminium CKN CONNECTION: THE STRONGEST TOOL CONNECTION FOR LIGHTWEIGHT...

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All BIG KAISER Precision Tooling Inc. catalogs and technical brochures

Archived catalogs

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4 Pages