Overview

This document details specialized tooling solutions for FANUC Robodrill machines, focusing on the BIG-PLUS spindle system and a comprehensive range of high-precision tool holders designed to enhance rigidity, precision, and interchangeability.

1. BIG-PLUS Spindle System Dual Contact

• Standard Feature: All FANUC Robodrill machines are equipped with the BIG-PLUS spindle system.
• Design Advantage: BIG-PLUS toolholders engage on the flange face rather than the gauge face, significantly improving rigidity compared to conventional steep taper holders.
• ATC Repeatability: Dual contact design ensures toolholder positioning accuracy within 1 micron during automatic tool changes, enhancing machining precision.
• Interchangeability: BIG-PLUS toolholders are backward compatible with standard spindles, but dual contact benefits are only realized with BIG-PLUS combinations.

2. MEGA Micro Chuck Series

• Design: Taper-off design reduces interference and maximizes rigidity.
• Specifications: Clamping range from Ø0.45 to Ø8.05 mm, maximum speed 40,000 min⁻¹, coolant-through hole available.
• Precision: Collet runout within 1 µm at the nose and 3 µm at the test bar end.
• Accessories: Includes MEGA nuts, wrenches, micro collets, seal nuts, protective cases, and taper cleaners.

3. MEGA New Baby Chuck

• Purpose: Ultra-precision collet holders for high-speed machining with a broad length and collet range.
• Clamping Range: Ø0.25 to Ø20 mm, max speed 40,000 min⁻¹, coolant-through hole.
• Features: Single-wrench easy clamping and optional adjusting screw for cutter length control.
• Accessories: MEGA nuts, wrenches, collets, perfect seals, and adjusting screws.

4. MEGA Double Power Chuck Type DS

• Characteristics: Near integral rigidity and precision of solid tool holders with flange-contacting nut for maximum rigidity.
• Coolant Supply: Unique design ensures efficient coolant delivery to the cutting tool periphery.
• Specifications: Clamping range Ø16 to Ø20 mm, max speed 30,000 min⁻¹.
• Adjustability: Optional axial length adjusting screw for precise tool length control.

5. New Hi-Power Milling Chuck Series

• Design: Slit structure supports heavy and finish end milling with high power and precision.
• Clamping Range: Ø16 to Ø32 mm, coolant-through hole.
• Models: HMC16S, HMC20S, HMC25S, HMC32S with corresponding OCA series collets and accessories.
• Features: Jet-through coolant for cutting tool periphery, adjustable cutter length, optional adjusting screws.

6. Hydraulic Chuck Series

• Applications: High precision machining in automotive, aerospace, medical, and die & mold industries.
• Clamping Range: Ø3 to Ø25 mm depending on model.
• Types: Standard, Super Slim, and Jet Through variants.
• Features: Coolant-through holes, ultra-precise clamping, slim design for tight spaces, optional adjusting screws with some limitations.
• Speed: Up to 30,000 min⁻¹ depending on model.

7. MEGA Synchro Tapping Holders

• Function: Compensates synchronization errors during rigid tapping, improving thread quality and tool life by reducing thrust loads up to 90%.
• Tapping Range: M1 to M20 depending on model.
• Coolant: Coolant-through hole available.
• Accessories: Tap holders in short, long, and extra-long lengths; MEGA wrenches.

8. Micro Collets and Accessories

• High precision micro collets for small diameter tools and taps.
• Accessories include MEGA wrenches, collet protective cases, seal nuts, and taper cleaners.
• Designed for rigid tapping and high-speed machining applications.

Critical Information and Best Practices

• Use BIG-PLUS toolholders with BIG-PLUS spindles to achieve dual contact and maximum rigidity.
• Ensure collets and nuts compatibility with specific chuck models.
• Observe maximum rotational speeds for each tool holder to prevent damage.
• Utilize coolant-through features to enhance tool life and machining quality.
• Use optional adjusting screws where applicable for precise tool length control, noting model-specific limitations.
• For tapping operations, verify machine tool supports rigid tapping functions.

Technical Specifications and Product Data Summary

1. Threaded Fasteners and Tap Holders

Detailed dimensions and weights for threaded fasteners (M10 to M20) and MEGA Synchro tapping holders in various lengths (150 mm, 200 mm) are provided, including nut and wrench ordering details.

2. Tool Holders and Side Lock Holders

Specifications for side lock holders (BBT30-TSL and BBT30-ISL series) include diameter, length, height, weight, and maximum tool shank length, facilitating precise tool selection.

3. Face Mill Arbor and Shrink Chuck Standards

Face mill arbors (FMH) feature coolant-through holes for improved cooling. Shrink chucks offer high rigidity with clamping diameters from 4 mm to 20 mm, precise tolerances (h5/h6), and coolant-through capabilities for carbide cutters.

4. Air Turbine Spindle and Accessories

Air turbine spindles (side through type) operate up to 120,000 min⁻¹, with included nuts and wrenches. Exclusive stop blocks and collets for small bore angle heads are specified with ordering information.

5. Milling Cutters: Fullcut Mill FCR and FCM

Fullcut mills support ramping, helical, square shoulder, and slot milling with clamping ranges from 16 mm to 32 mm. Detailed cutter dimensions, insert counts, insert sizes, and weights are provided. Inserts are categorized by ISO grades and coatings optimized for various materials (steel, stainless steel, cast iron, aluminum). Ordering details for inserts and wrenches are included.

6. Pullstuds, Tooling Accessories, and Precision Boring Heads

Pullstud bolts and wrenches compatible with JIS, MAS-I, MAS-II, and PMO30MG standards are detailed. Tooling mate accessories such as adapter lock screws and shanks for BIG KAISER precision boring heads are specified with dimensions and order numbers.

Additional Best Practices

• Use carbide cutters within specified tolerances (h5 or h6) for optimal performance.
• Order exclusive stop blocks and collets separately when required.
• Wrenches are included with some tools; inserts and nuts often require separate ordering.
• Select insert materials and coatings based on workpiece material and cutting conditions (e.g., ACP300 for steel, ACP200 for enhanced wear resistance).
• Coolant-through features in holders and arbors improve tool life and machining quality.

Summary

This document comprehensively covers tooling solutions optimized for FANUC Robodrill machines, emphasizing the BIG-PLUS spindle system's dual contact benefits and a wide range of precision chucks and holders. The tooling enhances machining rigidity, precision, and efficiency across milling, tapping, and high-speed machining applications, supported by detailed specifications, accessory options, and operational guidelines.