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BIG KAISER
High Performance Tooling Solutions Vol 2

High Performance Tooling Solutions Vol 2

Product catalog summary

Overview: The document is a comprehensive catalog of high-performance tooling solutions by the BIG DAISHOWA Group, detailing specifications, procedures, and recommendations for tool holders, boring tools, and accessories.

Tool Holders: Covers a wide range of tool holders including BCV/CV, BBT/BT, HSK, BIG CAPTO, CK/CKB, and cylindrical shanks, with detailed specifications and applications for different machining needs.

Boring Tools: Sections B.1 to B.6 detail rough and fine boring heads, large diameter boring heads, and indexable inserts, emphasizing the use of genuine parts for optimal performance.

Cutting Tools: Section C.1 highlights drills and mills, including indexable inserts and spade drills.

Accessories: Section D.1 lists tool holder accessories, measuring instruments, and tool assembly devices, emphasizing high-quality pullstud bolts for accuracy and safety.

BIG-PLUS Spindle System: Overview of the BIG-PLUS spindle system, highlighting benefits like improved surface finish, extended tool life, and enhanced machining accuracy through a dual contact system.

Key Specifications: Includes clamping ranges, spindle speeds, and compatibility information for tool holders and accessories, with cautionary notes on component use to maintain performance standards.

Conclusion: The catalog serves as a guide for selecting and using high-performance tooling solutions, emphasizing compatibility and quality for optimal machining results.

BIG-PLUS Conventional Gages: Lists North American licensed BIG-PLUS spindle rebuilders, emphasizing certified companies for spindle maintenance and rebuilding.

HSK Overview: Highlights premium material selection and strict dimensional accuracy control, explaining the importance of drive key form and tool retention features for rigidity and precision.

BIG CAPTO Overview: Describes the dual contact modular tooling system, emphasizing excellent repeatability and runout accuracy.

CK/CKB/CKN Tooling System Overview: Discusses the modular precision tool system by BIG KAISER, focusing on high efficiency, ease of handling, and compatibility with existing tools.

MEGA Chuck Series Overview: Highlights precision and balance for high-speed machining, detailing the notch-free design of the MEGA NUT and easy clamping mechanism of the MEGA WRENCH.

Collet Chuck Program Overview: Provides an overview of the collet chuck series, emphasizing high precision and rigidity in design.

MEGA Micro Chuck Overview: Focuses on the slim design and high precision, ideal for confined areas and high-speed micro machining.

MEGA New Baby Chuck Overview: Describes high-speed design and precision, emphasizing wide range and high precision capabilities.

MEGA ER Grip Overview: Details high precision and rigidity, noting superior runout accuracy and clamping force.

MEGA E Chuck Overview: Highlights high gripping strength and concentricity for end milling with high precision and rigidity.

MEGA Double Power Chuck Overview: Describes high rigidity design suitable for heavy cutting applications.

Specifications and Features: Details on various advanced chuck systems and tool holders designed for high precision and heavy-duty machining, emphasizing rigidity, precision, and effective coolant supply.

Procedures and Recommendations: Guidelines for effective end milling, secure clamping, and high precision applications.

Key Data and Performance Metrics: Includes cutting conditions, runout accuracy, and load reduction metrics.

Conclusion: Highlights the importance of selecting appropriate chuck and tool holder systems to enhance machining performance, precision, and tool longevity.

High Precision Boring Systems: Overview of various advanced boring systems and tools designed for machining centers, jig mills, boring mills, transfer machines, and high-speed milling machines.

Series 112 and 310 Boring Heads: High precision fine boring heads designed for accurate and high-performance boring operations.

Series 318 Boring System: Designed for large diameter boring, offering high-speed, lightweight aluminum construction.

Turning Systems: Describes various turning systems with modular construction and fine adjustment capabilities.

Smart Damper Technology: Eliminates chatter during machining, resulting in superior surface finishes and extended tool life.

Angle Heads: Designed to eliminate multiple set-ups by combining vertical, horizontal, and angular operations on one machine.

Air Power Spindle: Offers dynamic runout accuracy for micro-machining with high-speed capabilities.

High Spindle Holder: Improves drilling and end milling performance by multiplying spindle speed.

High Spindle and Coolant Supply: Reduces load on machine spindles, extending lifespan with multi-directional coolant supply.

Hi-Jet Holder: Designed for high-speed operations, supporting small diameter cutters.

Fullcut Mill: Offers high cutting performance with positive rake angles for smooth milling.

Speed Finisher: Optimized for aluminum and cast iron, improving surface finish in high-speed machining.

C-Cutter Mini: Compact chamfer mill with high feed rates and increased spindle speeds.

R-Cutter & Center Boy: Automate chamfering and centering processes with high efficiency and accuracy.

Compact Sensor Series: Quick detection of reference positions, minimizing machine downtime.

Measuring Instruments: High-quality test bars and measuring devices for ensuring machine tool precision.

Spindle System and Tool Alignment: Regular inspection of runout accuracy is recommended for extending machine lifespan.

Measuring Instruments: Various instruments for precision measurement and inspection tasks.

Tool Holding and Assembly: Devices for secure clamping and proper tool setup.

Cleaning Tools: Tools for maintaining cleanliness and accuracy of machine components.

Taper Standards: Outlines various taper standards with detailed specifications.

Balancing and Unbalance: Balancing of tool holders is crucial for high-speed machines to prevent vibration and spindle bearing failure.

Collet Chucks: MEGA MICRO CHUCK and MEGA NEW BABY CHUCK highlighted for clamping range and high RPM capabilities.

Hydraulic Chucks: Lists hydraulic chucks with clamping ranges and usage guidelines.

Shrink Fit Holders: Detailed specifications for various diameters and lengths.

Shell Mill Holders: Specifications for shell mill holders, emphasizing balancing with cutters for high-speed applications.

End Mill Holders: Specifications for end mill holders with clamping ranges.

Tapping Holders: Specifications for MEGA SYNCHRO TAPPING HOLDERS.

Modular Holders: Specifications for CKB shanks with dimensions and weights.

General Recommendations: Advises consulting machine tool manuals for compatibility and following operational manuals for equipment.

Angle Heads and Spindle Systems: Technical specifications and guidelines for various types of angle heads and spindle systems.

Specifications: Details on AG90 Compact Type, AG45 NBS, AG90 Slender Drive, AG90 Build-Up Type, AG90 HMC Type, AGU Universal Type, AGU30 Type, and Spindle Speeders.

Procedures and Recommendations: Guidelines for mounting, tool change, and coolant supply.

Limitations: NEW BABY END MILL COLLETS cannot be used with certain models.

Accessories: References various accessories with specific page numbers for further details.

HSK Angle Heads, Spindle Speeders, and Collet Chucks: Technical specifications and guidelines for various tool holder accessories.

Specifications: Details on HSK Angle Heads, Spindle Speeders, and Collet Chucks.

Procedures and Requirements: Guidelines for mounting, tool change, and coolant supply.

Recommendations and Cautions: Guidelines for tool rotation alignment and spindle speed adjustments.

Accessories: References various accessories with specific page numbers for further details.

Collets and Chucks: Detailed specifications and guidelines for various tool holder accessories.

Specifications: Lists various catalog numbers with corresponding dimensions and clamping ranges.

Procedures and Recommendations: Guidelines for collet usage and compatibility.

Accessories: References various accessories with specific page numbers for further details.

Warnings and Cautions: Guidelines for maintaining accuracy and avoiding compatibility issues.

ERC Collets: Detailed specifications and guidelines for ERC collets, focusing on precision and rigidity.

Specifications: Lists catalog numbers and clamping ranges for different ERC models.

Procedures and Recommendations: Guidelines for maintaining accuracy and avoiding compatibility issues.

Accessories: Describes various nuts and wrenches compatible with MEGA ER chucks.

Performance and Limitations: Highlights the importance of using the correct collet size for optimal performance.

Cleaning and Maintenance: Emphasizes the importance of using cutting tool shanks with diameters matching the collet bore diameter.

Conclusion: Provides comprehensive information on ERC collets, emphasizing precision and compatibility.

Tool Holder Accessories: Detailed specifications and descriptions of various tool holder accessories.

Torque Wrenches: Designed for the MEGA CHUCK series, featuring a torque limiter.

Digital Torque Wrenches: Includes Mega Wrench Adapters with specific features.

Cleaners: Describes the Wiper Cleaner and TK Cleaner for hydraulic chucks and shrink fit holders.

Screws: Specifications for screws used in hydraulic chucks.

Grip Bars: Used for confirming gripping force in hydraulic chucks.

Tap Holders: Available in various lengths and styles, compatible with different standards.

Accessories: References additional accessories with page numbers for further details.

CKB Heavy Metal Boring Bars and Fine Boring Heads: Technical specifications and guidelines for rough and fine boring operations.

Specifications: Designed for roughing operations, offering higher rigidity and vibration damping.

Procedures: Guidelines for using HMC chucks and cutting data for various materials.

Insert Selection & Cutting Data: Recommended inserts and cutting data for different materials.

Power Consumption: Guidelines for calculating power requirements.

Troubleshooting: Common problems and remedies for boring operations.

Fine Boring Heads: Describes various fine boring heads with digital models and wireless communication capabilities.

Accessories and Spare Parts: References accessories and spare parts with catalog numbers.

Fine Boring Heads: Detailed specifications and features of fine boring heads.

Specifications: Details on EWB AL, EWB-UP, and EWN series.

Features: Wireless communication and Smart Damper System for enhanced performance.

Accessories and Spare Parts: References various insert holders and shanks.

Application Advice: Guidance on optimal cutting parameters and tool configurations.

Key Data: Resolution and catalog numbers for precise selection and application.

Large Diameter Boring Heads: Technical specifications and guidelines for large diameter boring heads.

Materials and Specifications: Details on various materials and machining parameters.

Cutting Data and Recommendations: Critical conditions for fine boring insert selection and cutting data.

Large Diameter Boring Heads: Details on Series 318 boring heads and component selection tables.

Accessories and Spare Parts: References accessories and spare parts with catalog numbers.

Cutting Materials Overview: Detailed overview of various cutting materials and their applications.

Specifications and Applications: Categorizes inserts based on suitability for different materials.

Coating Remarks: Details on various coatings and their benefits.

Indexable Inserts Details: Specifications for indexable inserts with comprehensive tables.

Application Advice: Guidance on selecting the appropriate insert for specific machining tasks.

Conclusion: Comprehensive guide for selecting and applying indexable inserts in machining operations.

Indexable End Mills: Detailed specifications and guidelines for various types of indexable end mills.

Specifications: Lists multiple catalog numbers with corresponding dimensions and insert models.

Procedures and Recommendations: Guidelines for coolant pipes, clamping screws, and safety enclosures.

Cutting Parameters: Guidelines for selecting cutting speeds and feeds based on work material and insert grade.

Insert Classifications: Inserts classified by ISO material grades and coatings.

Key Tables and Data: Tables list maximum and minimum traverse, ramping angles, and hole diameters.

Warnings and Cautions: Guidelines for insert usage and compatibility.

Material Specifications and Insert Grades: Details on various insert grades and their applications.

Chamfer Mills and C-Cutter Features: Designed for a wide range of chamfering diameters.

Insert Coatings and Applications: Details on different coatings and their benefits.

Cutting Data and Recommendations: Cutting speed and feed recommendations for various materials.

Micro and Centering Cutters: Suitable for complex shapes with specific cutting speeds and feeds.

Accessories and Spare Parts: Lists various accessories and emphasizes periodic ordering of consumables.

Safety and Operational Guidelines: Safety precautions and recommendations for maintaining low runout during machining.

Specifications: Details on probe repeatability, over-travel, measuring pressure, and battery life.

Product Models and Features: Details on PMC and PMG series, Base Master, and Base Master Mini.

Accessories: Various stylus models, ATC Alignment Tool, and Dyna Force.

Key Features: LED notification, replaceable stylus, and conductivity.

Recommendations: Guidelines for using standard accessory stylus and high precision leveling.

Specifications: Details on measuring instruments and tool assembly devices.

Procedures: Instructions for using measuring instruments and tool assembly devices.

Standards and Recommendations: Emphasizes high-quality materials and construction for durability and precision.

Accessories and Adapters: Various accessories and adapters for customization and enhanced functionality.

Key Data from Tables: Detailed tables with dimensions, load capacities, and catalog numbers.

Specifications and Recommendations: Recommended spindle speed ranges and guidelines for use.

Chip & Coolant Fan: Provides fast, safe chip and coolant cleaning.

T-Slot Clean: Improves work safety and efficiency by quickly removing chips.

Company Overview: BIG DAISHOWA designs and manufactures high-precision tooling systems for various industries.

Catalog excerpts

HIGH PERFORMANCE TOOLING SOLUTIONS VOL. 2

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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

Open the catalog to page 3

High Performance Tooling Solutions Vol 2-4

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.500"-1.500" (Ø12-50mm) OVERVIEW X22 MEGA DOUBLE POWER CHUCK MILLING CHUCKS MILLING CHUCKS HYDRAULIC CHUCKS CLAMPING RANGE: Ø.750"-1.250" (Ø16-32mm) OVERVIEW X23 CLAMPING RANGE: Ø.500"-1.500" (Ø16-42mm) OVERVIEW X25 CLAMPING RANGE: Ø.125"-1.250"...

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High Performance Tooling Solutions Vol 2-5

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

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High Performance Tooling Solutions Vol 2-6

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 TOOL HOLDER ACCESSORIES BIG-PLUS CLEANER OVERVIEW X57 HIGH-PRECISION TEST BAR DYNA TEST FINE BORING ROUGH & FINISH BORING

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High Performance Tooling Solutions Vol 2-7

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 2-8

INDEX CHAMFER MILLS RADIUS MILLS BACK SPOT FACING TOOL GROOVE MILLING TOOLS MEASURING INSTRUMENTS GROOVE MILLING CUTTERS WITH CARBIDE INSERTS MEASURING INSTRUMENTS TOUCH PROBE & EDGE FINDER TOOL OFFSET SENSOR MEASURING INSTRUMENTS MEASURING INSTRUMENTS MEASURING INSTRUMENTS TOOL OFFSET SENSOR TOUCH PROBE & EDGE FINDER MEASURING DEVICE FOR PULLING FORCE

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High Performance Tooling Solutions Vol 2-9

INDEX MEASURING INSTRUMENTS MEASURING INSTRUMENTS TOOL ASSEMBLY DEVICES TOOL HOLDING DEVICES PRECISION MACHINE LEVEL DIAL INDICATOR STANDS TOOL ASSEMBLY 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 2-10

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...

Open the catalog to page 10

High Performance Tooling Solutions Vol 2-11

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 2-12

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 2-13

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 2-14

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...

Open the catalog to page 14

High Performance Tooling Solutions Vol 2-15

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...

Open the catalog to page 15

High Performance Tooling Solutions Vol 2

High Performance Tooling Solutions Vol 2

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