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BIG KAISER
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, boring tools, cutting tools, and accessories.

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 section provides detailed specifications and clamping ranges for different shank types, highlighting their maximum RPM capabilities.

Boring Tools: Sections B.1 to B.6 detail rough and fine boring heads, large diameter boring heads, and indexable inserts. Key specifications such as diameter ranges and smart damper systems are highlighted to enhance precision and reduce vibration during operations.

Cutting Tools: The catalog includes sections on indexable inserts, spade drills, and various milling tools. It emphasizes the importance of using high-quality inserts for optimal performance and longevity.

Accessories: A variety of tool holder accessories are listed, including pullstud bolts, high-precision test bars, and alignment tools. The catalog stresses the importance of using genuine BIG DAISHOWA accessories to maintain accuracy and performance.

BIG-PLUS Spindle System: A significant portion of the document is dedicated to the BIG-PLUS spindle system, which offers simultaneous taper and flange fit for improved surface finish, dimensional accuracy, and tool life. The system is compatible with existing machines and tool holders, providing enhanced rigidity and reduced deflection.

Measuring Instruments: The catalog also includes a section on measuring instruments such as presetters, touch probes, and tool offset sensors, which are essential for maintaining precision in machining operations.

Recommendations: The document advises on best practices for tool holder maintenance, including the use of proper pullstud bolts and cleaners to ensure longevity and performance.

Machine Spindle Deflection: The document discusses the deflection of a machine spindle tested on a vertical machine, emphasizing the importance of strict gage control for maintaining precision in spindle rebuilds.

HSK Tooling System: The HSK system is highlighted for its premium material selection and strict dimensional accuracy control. It uses high-grade alloy steels, particularly for smaller sizes, to ensure optimal performance. The system includes various forms and sizes, adhering to ISO, DIN, and ASME standards.

BIG CAPTO System: This dual contact modular tooling system enhances the performance of machine tool centers (MTCs) with excellent repeatability and runout accuracy. It offers a wide range of rotating tooling options and is known for its efficiency and material selection.

CK/CKB/CKN Tooling System: The document describes the modular precision tool system by BIG KAISER, which is known for its high interchange accuracy and compatibility with existing tools. The CKN connection is designed for lightweight and high-performance tools, offering significant weight reduction without compromising cutting performance.

MEGA Chuck Series: This series offers a variety of collets and chuck bodies for high-speed ultra-precision machining. The MEGA CHUCKS are precision ground and balanced, featuring a notch-free design to prevent vibration and reduce noise.

Collet Chuck Program: The program provides a wide range of collet chuck series with different taper types and sizes, ensuring high precision and rigidity for various machining applications.

MEGA Micro Chuck Overview: Designed for high-speed micro machining, the MEGA Micro Chuck offers a slim design for superior balance and concentricity, ideal for reaching confined areas.

MEGA New Baby Chuck Overview: This chuck series is designed for high-speed precision machining, utilizing ultra-precise collets to guarantee minimal runout and high accuracy.

MEGA ER Grip Overview: The MEGA ER Grip system offers high precision and rigidity, outperforming standard ER systems with improved runout accuracy and clamping force.

MEGA E Chuck Overview: Specifically designed for end milling, the MEGA E Chuck provides high gripping strength and concentricity, ensuring better surface finishes and longer tool life.

Spindle Systems: The document highlights the benefits of reinforced locating pin assemblies and bearings that increase rigidity and reduce load on machine spindles, thereby extending their lifespan. The HIGH SPINDLE system is designed to operate at high speeds with reduced load, enhancing spindle longevity.

Coolant Supply: Multi-directional coolant supply systems are discussed, with universal nozzles adjustable to tool length for optimal coolant delivery. The HIGH SPINDLE can operate without coolant through the housing, and specific models allow pinpoint coolant delivery for short tools.

Hi-JET Holder: This section describes the Hi-JET HOLDER, which supports 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 suitable for small diameter cutters.

Fullcut Mill: The Fullcut Mill offers sharp cutting edges with high radial and axial rake angles, providing smooth and quiet milling. It is designed for high toughness and reduced edge chipping, with unique inserts for multifunctional cutting.

Speed Finisher: This tool combines lightweight design with high rigidity, allowing for quick adjustment of cutting edge height and direct coolant supply to the cutting edge. It is suitable for high-speed machining of aluminum and cast iron.

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

Compact Sensor Series: The document outlines various sensors for quick detection of reference positions and tool offsets, suitable for conductive and non-conductive materials. These sensors help minimize machine downtime and ensure precision in machining operations.

Measuring Instruments: BIG DAISHOWA provides high-quality test bars for precision standards, ensuring accurate machine runout inspections and tool clamp measurements. Regular inspections are recommended to maintain machine tool performance.

Modular Holders: The document lists various modular holders with specifications such as catalog number, reference number, figure, CK number, diameter (ØD), length (L), and weight. These holders are designed for extension and reduction purposes in machining.

Boring Heads: Specifications for rough and fine boring heads are provided, including dimensions and weight. The document highlights the importance of using the correct boring head for specific applications to ensure precision and efficiency.

Angle Heads: Detailed information on AG90 and AG45 angle heads is included, specifying clamping ranges, dimensions, and maximum RPM. The document emphasizes the need for a stop block when mounting these heads and notes that automatic tool change may not be available for all machine models.

BIG CAPTO Shanks: This section outlines the specifications for BIG CAPTO shanks, including diameter, length, and weight. It cautions about potential interference with tool changes on older machines.

Accessories and Spare Parts: The document references pages for accessories such as collets, wrenches, and stop blocks, which are essential for the proper functioning and maintenance of the machining components.

Key Considerations: Ensure compatibility of components with specific machine models to avoid operational issues. Follow the recommended guidelines for mounting and using the components to maintain safety and performance. Consult engineering for specific information about machine compatibility and potential interference issues.

Milling Chucks: The document lists several models of milling chucks, such as BBT50-MEGA16DPG-105, with specifications including diameter, length, and weight. Key grips and springs are included, but wrenches must be ordered separately.

Hydraulic Chucks: Specifications for hydraulic chucks cover clamping ranges from Ø.250" to Ø1.250". The document details dimensions, maximum RPM, and weight for each model.

Procedures and Recommendations: Key grips should be replaced immediately if worn or damaged to ensure safe operation. When using coolant supply from the cutting edge, a seal bush is necessary instead of the spring, which must be ordered separately. For hydraulic chucks, it is advised not to use cutting tools with a flat on the shank and to ensure the tool is inserted beyond the minimum clamping length.

Standards and Compliance: The document references JIS B4005 standards, which align with ISO3338-2 and DIN1835-1, for cylindrical shanks with flat sections. JIS standards require sizes Ø25 or higher to be double-flat types, although the MEGA PERFECT GRIP does not use a rear flat surface.

Accessories: Various accessories such as wrenches, seal bushes, and adjusting screws are mentioned, with specific catalog numbers provided for ordering.

Safety and Maintenance: Regular maintenance and immediate replacement of worn parts are emphasized for safe operation. Specific cautions are provided regarding the use of hydraulic chucks, including the prohibition of tightening the clamping screw without a tool inserted.

Hydraulic Chucks: The document lists various models of hydraulic chucks, including HSK-A63, HSK-A100, and HSK-A125, with specific measurements for diameter, length, and weight. The clamping range is specified for different tool sizes, and maximum RPMs are provided for each model.

Procedures and Recommendations: Users are advised to use cutting tools with a shank tolerance of h6 and avoid tools with a flat shank. Roughing end mills are not recommended. It is crucial to insert the cutting tool into the hydraulic tool holder beyond the minimum clamping length before tightening the clamping screw.

Accessories: The document mentions the need for separate orders for coolant pipes and adjusting screws. It also provides guidelines for using shrink fit holders and basic arbors, emphasizing the importance of using genuine side lock screws for end mill holders.

Figures and Tables: Several figures illustrate the components and assembly of the hydraulic chucks, including manual clamping holes, coolant pipes, and adjusting screws. Tables provide detailed measurements and specifications for each model, including catalog numbers and weight.

Cautionary Notes: Users are cautioned against balancing without consulting the manufacturer and are advised on the compatibility of heating/cooling equipment with the tools. The document stresses the importance of using the correct accessories and following the specified procedures to ensure safety and optimal performance.

SMART Damper Milling: Face Mill Arbor Type with coolant through capability. Includes hook wrench and cutter clamping screw; coolant pipe must be ordered separately. Damper head is non-removable once attached.

MEGA Synchro Tapping Holders: Available in various sizes with specific tapping ranges (e.g., No.2-AU3/4, M2-M20). Coolant pipe, tap holder, and wrench must be ordered separately. Requires a machine tool with a rigid tapping function.

Modular Holders: CKB and CKN shank types with various dimensions and weights. Includes reference numbers for easy identification. Coolant pipe is optional and must be ordered separately.

Angle Heads: AG90 NBS Type with clamping range Ø.010"-.787". Includes nut and wrench; coolant pipe and collet must be ordered separately. Stop block required for mounting; automatic tool change may not be available for all machine models.

Key Recommendations: Ensure compatibility of clamping screws and other accessories by referring to the specified pages in the manual. Order necessary accessories separately to ensure complete setup. Follow cautionary notes regarding tool usage and machine compatibility.

Angle Heads: The document details different models of angle heads, such as AG45, AG90, and AGU Universal types, with clamping ranges from Ø.060" to Ø.787". Each model has specific dimensions, weight, and speed ratios, with maximum RPMs ranging from 2,000 to 6,000.

Spindle Speeders: The RBX5 and RBX7 models are designed for high-speed micro machining, with operating spindle speeds between 40,000 and 80,000 RPM. They require clean compressed air and are not compatible with coolant through the spindle.

Collet Chucks: MEGA Micro Chucks are available with clamping ranges from Ø.018" to Ø.317" and are suitable for micro drill and end mill applications, with maximum RPMs up to 50,000.

Procedures and Requirements: A stop block is mandatory for mounting angle heads on machines, and it must be ordered separately. Coolant can be ejected from the housing when supplied through the stop block. Automatic tool change may not be available for all machine tool models. NEW BABY END MILL COLLETS are not compatible with these tools.

Recommendations and Cautions: The rotation of the cutting tool may be in the same or reverse direction of the machine spindle, depending on the model. Ensure that the compressed air used for spindle speeders is clean to avoid damage. When using collet chucks, gradually increase the spindle speed to the appropriate level to account for machine rigidity and tool balance.

Accessories: The document lists necessary accessories such as collets, wrenches, and stop blocks, with page references for ordering.

MEGA MICRO CHUCK: Clamping Range: Ø.018"-.238" (Ø.45-6.05mm). Applications: Micro Drill & End Mill. Max RPM: 50,000. Includes MEGA MICRO NUT; coolant pipe, collet, and wrench must be ordered separately. Practical spindle speed may be influenced by machine rigidity and tool balance.

MEGA NEW BABY CHUCK: Clamping Range: Ø.010"-.787" (Ø.25-20mm). Applications: Drills, Reamers, Taps & Finishing End Mills. Max RPM: 40,000. Includes MEGA NEW BABY NUT; coolant pipe, collet, wrench, and adjusting screw must be ordered separately. Practical spindle speed may be influenced by machine rigidity and tool balance.

Hydraulic Chucks: Ultra Precision Super Slim: Clamping Range Ø.125" (Ø3-6mm), Max RPM: 60,000. Super Slim: Clamping Range Ø.125" (Ø3-12mm), Max RPM: 60,000. Coolant pipe must be ordered separately; adjusting screws cannot be used.

General Recommendations: Use only cutting tools with a shank tolerance of h6. Do not use with cutting tools made with a flat on the shank (e.g., Weldon type shank). Roughing end mills are not recommended for use with hydraulic chucks. Always insert the cutting tool into the hydraulic tool holder beyond the minimum clamping length "E".

Accessories: Collet, MEGA Nut, Seal Nut, MEGA Wrench, and other accessories are listed with page references for ordering.

Cartridge-Turning Adapters: These adapters are screw-on types designed for positive inserts. They include a carbide shim for DN1506 inserts, with an option to replace it with a DNS1504C shim for DN1504 inserts. Wrenches and screws for the carbide seat are included, but the wrench for tightening the clamp piece and inserts must be ordered separately.

Specifications: The document lists various catalog numbers with specifications such as insert type, hand orientation, dimensions, clamp piece, carbide shim, and weight. For example, the B32-DDUNR-22032-11 model uses a DN1104 insert, is right-handed, and has specific dimensions and components.

Carbide Shim Set: This section details the catalog numbers for different carbide shims, screws, and Torx sizes compatible with various inserts. It specifies the necessary components for each setup, such as the SDNS1506 shim for DN1506 inserts.

Carbide Clamp Set: The document outlines the components of the clamp set, including the clamp piece, screw, spring, and compatible inserts. For instance, the SCP2 model is compatible with CN1204, TN2204, DN1504, and DN1506 inserts.

Accessories: Various accessory sets are mentioned, such as the clamp screw set for type S basic holders and the insert clamping screw set for VB1604/VC1604 inserts. These sets include screws and wrenches necessary for assembly.

Tool Holder Accessories: This section covers a range of accessories for tool holders, including collets, nuts, and chucks. It highlights the precision and clamping capabilities of products like the MEGA Micro Collet and the NEW BABY Collet, known for their high accuracy and precision.

Collets: The document provides detailed specifications for various collets, including clamping ranges and catalog numbers. It emphasizes the high precision and guaranteed maximum runout of these collets, which are inspected for accuracy.

Nuts: The MEGA Micro Coolant Nut is designed for efficient coolant supply in micro machining, offering up to 35% higher tool lifetime compared to standard nuts. Specifications for different models are provided, including dimensions and replacement parts.

Series 319 SW Back Boring and Chamfering Insert Holders: The 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.

Specifications: Insert holders are available in short (S) and long (L) types, designed for full-profile roughing. Back boring insert holders cover diameters from Ø1.732" to 8.307" and must be mounted on the RSS/BALANCED side of the boring head. Chamfering insert holders allow for adjustable chamfering angles from 15º to 75º.

Procedures: Insert holders must be mounted correctly to ensure optimal performance. Face grooving holders can be used to manufacture grooves in diameters ranging from Ø2.087" to 8.000".

Cutting Data and Recommendations: Recommended inserts and cutting data are provided for various materials, including mild steels, high carbon alloy steels, stainless steels, cast iron, high temp alloys, and non-ferrous materials. Maximum cutting speed is 4,000 SFM, and adjustments may be necessary based on machine power curves.

Troubleshooting: Common issues such as poor chip control, chatter, vibration, and insert chipping are addressed with potential remedies. Recommendations include adjusting feed rates, reducing speed, and ensuring stable workpiece support.

Key Parameters: Maximum back bore diameter and body diameter calculations are provided. Insert selection is based on tool length/diameter ratio and depth of cut requirements.

Accessories and Spare Parts: Detailed references to accessories and spare parts are provided, with page numbers for further information.

Fine Boring Operations: 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 information for various fine boring heads.

Specifications: The document outlines the 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 troubleshooting advice for common issues such as poor tool life, excessive cutting speed, and insufficient machine power. Recommendations include adjusting feed rates, changing inserts, and increasing coolant pressure. It also addresses issues with chip evacuation and excessive exit burrs.

Accessories and Compatibility: Accessories for the EWE and EWN series are fully compatible, allowing for flexible and efficient operations. The document lists various accessories and spare parts, including insert holders and tool holders, with specific catalog and reference numbers for easy identification.

Recommendations: The document emphasizes the importance of selecting the correct insert and cutting data to optimize performance. It also highlights the benefits of using the BIG KAISER app for calculating cutting data and maintaining a history of adjustments.

Key Data: The document includes tables with detailed measurements and specifications for each boring head, such as diameter ranges, maximum RPM, and coolant pressure limits. These data points are crucial for ensuring precise and efficient machining operations.

Fine Boring Tools: The document provides detailed specifications and guidelines for fine boring heads and inserts used in machining various materials. It includes data on cutting speeds, feed rates, and insert selection for different materials such as cast iron, high-temperature alloys, copper alloys, aluminum/magnesium, and tool steel.

Specifications: The document lists various insert types (e.g., CCMT, TCMT) with specific dimensions and cutting parameters. It provides cutting speed ranges (SFM) and feed rates (IPR) for different materials, emphasizing the importance of selecting the right insert and cutting conditions to achieve optimal machining results.

Procedures: Fine boring guidelines are outlined, focusing on the balance between stock removal, feed rate, and cutting speed. The document highlights the risks of excessive cutting forces and chatter when parameters are not optimized.

Recommendations: For stable cuts, it is recommended to maintain a depth of cut (D.O.C.) greater than half the insert nose radius and a feed rate larger than the hone on the insert tip. Higher cutting speeds are suggested for better surface finishes and shorter machining times, while lower speeds may lead to poorer finishes and increased tool wear.

Tools and Accessories: The document describes various fine boring heads, including EWE digital heads with wireless communication capabilities, EWN single cutter heads, and EWB balanced heads. It also covers the SMART DAMPER system for vibration reduction and lists compatible shanks and insert holders.

Data Interpretation: Tables and charts provide cutting data without guarantees, emphasizing the need for careful selection and adjustment of tools based on specific machining conditions. The document includes a section on troubleshooting and application advice to assist users in optimizing their machining processes.

Fine Boring Tools: The document provides detailed specifications and guidelines for using fine boring tools, particularly focusing on vibration-free finishing operations in bores with unfavorable diameter-to-length ratios. It includes information on boring bars, insert holders, and accessories, along with troubleshooting advice and cutting data for various materials.

Specifications: The document lists various boring heads and their specifications, including catalog numbers, reference numbers, dimensions, and weight. It covers different types of boring bars and their compatibility with specific inserts and accessories.

Procedures: Detailed procedures for fine boring operations are provided, including recommended cutting speeds, feed rates, and insert types for different materials such as mild steel, high carbon alloy steel, stainless steel, cast iron, high-temperature alloys, copper alloys, and aluminum/magnesium.

Troubleshooting: Common problems in fine boring operations are addressed with possible causes and remedies. Issues such as poor tool life, chatter and vibration, poor size repeatability, unacceptable roundness, and poor surface finish are discussed with solutions like adjusting speed, changing insert grades, and improving cooling.

Recommendations: The document recommends optimal conditions for fine boring, including maintaining a length-to-diameter ratio of less than 4:1, ensuring rigid fixtures and workpieces, and using good machine spindles. It also provides guidance on insert selection and cutting data under both optimal and critical conditions.

Large Diameter Boring: An overview of large diameter boring heads is provided, detailing the Series 318 with various configurations for rough and fine boring, OD turning, chamfering, and face grooving. The system uses aluminum extension slides and components for precise tool assembly.

Accessories and Spare Parts: The document lists various accessories and spare parts, including insert holders for chamfering and face grooving, clamp bases, and extension slides. It provides catalog numbers and specifications for each component.

Key Data Tables: Several tables are included, summarizing cutting data for different materials, recommended insert types, and optimal cutting conditions. These tables are crucial for selecting the right tools and settings for specific boring operations.

Specifications: The document provides detailed specifications for various materials including Grey Cast Iron, Ductile/Nodular Cast Iron, Aluminum & Non-Ferrous metals, and different types of steel. It includes parameters such as tensile strength and recommended feed rates for drilling operations.

Procedures: The document outlines procedures for stationary drilling and the use of adjustable drill holders. It emphasizes the importance of safety measures, such as using safety guards during through-boring operations to prevent accidents from centrifugal force.

Standards and Recommendations: The document adheres to standards like ASME B5.50 for adjustable drill holders and provides guidelines for selecting cutting parameters. It recommends dry cutting for stainless steel to avoid fire hazards associated with oil-based cutting fluids.

Tools and Accessories: Detailed information is provided on various cutting tools, including indexable insert drills and fullcut mills. The document lists catalog numbers, dimensions, and weight for different tool models, along with the number of inserts required.

Key Data from Tables: The tables include data on drill diameters, thrust requirements, and adjustable range bore diameters for different insert sizes. They also provide cutting speeds and feed rates for various materials and tool sizes.

Safety and Caution: The document includes cautionary notes about the risks of using incorrect inserts and the importance of maintaining correct clamping force by regularly replacing clamping screws and wrenches.

Fullcut Mill Type FCM: The document provides detailed specifications and guidelines for the Fullcut Mill Type FCM, an indexable end mill tool used in machining. It includes information on various models, their dimensions, and the corresponding inserts required for operation.

Specifications: The Fullcut Mill is available in both inch and metric styles, with different taper shank adapters (40 and 50 taper). The document lists catalog numbers, dimensions (diameter, length, effective cutting edge), number of inserts, insert models, and weight for each tool variant.

Inserts: Inserts are a critical component of the Fullcut Mill, with specific models designated for each cutter diameter. The document emphasizes that inserts must be ordered separately and provides a detailed table of insert sizes, grades, and suitable materials. It also highlights the importance of using the correct insert to avoid operational issues.

Accessories: Accessories such as coolant pipes and clamping screws are mentioned, with a note that these must be ordered separately. The document advises regular replacement of clamping screws and wrenches to maintain proper clamping force.

Recommendations: The integral version of the Fullcut Mill is recommended for machines with small spindle tapers due to its increased rigidity and cost savings from not requiring a tool holder. The document advises caution when using the HSK-E type interface due to potential slippage if cutting loads exceed clamping force.

Limitations: The Fullcut Mill Type FCM is not suitable for feeding in the Z-axis, such as ramping, plunging, and boring. It is designed for medium-heavy and finish-light cutting operations.

Cutting Data: The document provides cutting data for various work materials, including carbon steel, alloy steel, unalloyed steel, and prehardened steel, with recommendations for insert selection based on material properties.

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

Specifications: The C-Cutter Mini series includes models with different chamfering angles (30º, 45º, 60º) and sizes, allowing for a wide range of applications. The document lists specific dimensions for each model, including diameter, length, and chamfering range.

Inserts and Accessories: Inserts are available in different grades and coatings, such as ACP200, ACP300, and DLC, each suited for specific materials like steel, aluminum, and cast iron. Accessories include wrenches and screws, which are necessary for insert installation.

Cutting Conditions: The document provides recommended cutting speeds and feeds for various materials, emphasizing the importance of adjusting parameters based on machine and workpiece conditions. Wet cutting is generally recommended for better surface finishes.

Recommendations: For optimal performance, it is advised to use standard inserts for long types to avoid chatter and to regularly replace clamping screws and wrenches to maintain proper clamping force. The document also suggests using high-rigidity holders to minimize tool vibration.

Applications: The C-Cutter Mini is suitable for both front and back chamfering, including complex shapes and deep holes. It is designed to reduce the number of tools required and improve efficiency in tool change operations.

Safety and Maintenance: Users are cautioned to keep tool projection lengths short and to use protective equipment to prevent injuries from hot tools or scattering chips. Regular maintenance and proper handling are emphasized to ensure tool longevity and performance.

Specifications: The document provides detailed specifications for various cutting tools, including chamfer mills, centering cutters, and radius mills. It includes dimensions, catalog numbers, and insert models for each tool type. The tools are designed for specific applications such as spot drilling, chamfering, and back counterboring.

Procedures: Recommended cutting conditions are outlined for different materials such as carbon steel, stainless steel, cast iron, and aluminum. The document advises on cutting speeds (Vc) and feed rates (fz) for optimal performance. It also provides guidelines for using water-soluble cutting fluids and dry cutting techniques.

Standards and Recommendations: The document emphasizes the importance of adjusting cutting conditions based on machine tool and workpiece conditions. It recommends using water-soluble cutting fluids during spot drilling and dry cutting for traverse chamfering, with exceptions for aluminum machining.

Key Data from Tables and Charts: Tables provide cutting speed and feed rate recommendations for various materials and tool types. They also list insert models and grades, along with their applications and material compatibility. The document includes detailed dimensions and specifications for each tool, aiding in selection and application.

Critical Information: Use of water-soluble cutting fluid is recommended for spot drilling. Dry cutting is preferred for traverse chamfering unless a built-up edge occurs. Inserts must be ordered separately, and regular replacement of clamping screws and wrenches is advised. Cutting conditions should be adjusted based on machine and workpiece conditions to ensure optimal performance.

Technical Specifications and Components Overview:

Adapter Arms and Extensions: Various adapter arms are available with different extension capacities and load capacities. For instance, the DGH3 model offers a 354mm extension and can support up to 220 lbs (100 kgs). The dimensions of the magnets used in these adapters are consistent across models, measuring 53mm x 60mm x 68mm.

Measuring Instruments and Stands: Dial indicator stands are designed for precision measurement tasks. They feature rigid construction with options for magnetic or shank-based mounting. The stands can be equipped with various adapters for different measurement needs, including cylindrical gage adapters.

Tool Assembly Devices: These devices facilitate the assembly and disassembly of tooling systems. They include features like 360-degree rotation and secure clamping mechanisms. The devices are compatible with various taper sizes, including HSK and ISO standards.

Cleaners: Cleaning tools are essential for maintaining precision and prolonging the life of machine tools. The catalog includes spindle cleaners, chip blowers, and chip fans, each designed to remove debris and coolant efficiently. These tools are made from durable materials and are designed for high-speed operation.

Accessories: Various accessories are available to enhance the functionality of the primary tools and devices. These include additional adapters, clamping systems, and cleaning strips, all designed to improve efficiency and precision in industrial applications.

Operating Instructions and Coolant System: This document provides operating instructions for a coolant system designed to improve work safety and efficiency in table cleaning. The system facilitates quick removal of chips from machines, reduces clean-up time, and enhances machining precision by controlling the volume of heated chips. The coolant also helps prevent thermal displacement of the machine.

Specifications and Accessories: The document lists various T-Slot cleaners available in different sizes to fit machine tables. These include:

TS18-1000L-10P: 18mm width, 1,000mm length, 10 pieces
TS22-1000L-10P: 22mm width, 1,000mm length, 10 pieces
TS14-400L-100P: 14mm width, 400mm length, 100 pieces
TS18-400L-100P: 18mm width, 400mm length, 100 pieces
TS22-400L-100P: 22mm width, 400mm length, 100 pieces

Each set includes a removal pin for easy removal and can be cut to the required length.

Company Overview: BIG DAISHOWA is a global manufacturer of high-precision tooling systems and solutions for various industries, including automotive, military, aerospace, energy, and micro-technology. The company has facilities in Japan, Switzerland, Germany, and the USA, and offers a product portfolio of over 20,000 precision tools.

Product Offerings: BIG DAISHOWA provides a wide range of products, including:

Boring Tools: Rough, Fine, Large Diameter, Digital, and Automatic Boring
Tool Holders: BIG-PLUS, HSK, BIG CAPTO, Collet Chucks, Milling Chucks, Hydraulic Chucks, Spindle Attachments
Turning Tools: CNC Lathe Tooling, Multi-Axis Turning Tools, Swiss Automatic Lathe Tooling
Cutting Tools: Indexable, Solid Carbide, High-Speed Steel (HSS)
Tool Measuring & Management: Tool Presetters, Tool Management, Measuring Devices
Zero-Point Workholding: Round Chucks, Preassembled Chucks, Multi-Axis Systems, Chain Clamping, Stabilizer System

Contact Information: BIG DAISHOWA Inc. is located at 2600 Huntington Blvd, Hoffman Estates, IL 60192. For inquiries, contact via phone at (224) 770-2999 or email at [email protected].

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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High Performance Tooling Solutions Vol 3

High Performance Tooling Solutions Vol 3

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