BIG KAISER High Performance Tooling Solutions 2018-2019

HIGH PERFORMANCE TOOLING SOLUTIONS 2018-2019

A Member of the BIG DAISHOWA Group

PREMIUM PROVIDER OF TOOLING SOLUTIONS Tooling for advanced metalworking environments, from standard production machining challenges to extreme precision and complex applications,

these superior products deliver lower costs through higher efficiency. With our superior technologies and state-of-the-art production facilities, we guarantee to offer "High Precision" and "High Quality" tools to your satisfaction.

This Catalog Contains Patents and Trademarks of the BIG DAISHOWA Group Pending and Patented at the U.S. Patent Office

2

A.1 56-105 A.2 106-167 A.3 168-229 A.4 230-259 A.5 260-273 A.6 274-297 A.7 298-331 A.8 332-391 B.1 392-411 B.2 412-451 B.3 452-475 B.4 476-505 B.5 506-527 C.1 528-593 D.1 594-623

BCV/CV SHANKS

BBT/BT SHANKS

HSK SHANKS

BIG CAPTO SHANKS

CK/CKB SHANKS

CYLINDRICAL SHANKS N/C LATHE TOOLING

MILLTURN TOOLING

TOOL HOLDER ACCESSORIES

ROUGH BORING HEADS

CENTRIC CUTTING EDGE FINE BORING HEADS

PERIPHERICAL CUTTING EDGE FINE BORING HEADS

LARGE DIAMETER BORING HEADS

INDEXABLE INSERTS

CUTTING TOOLS

ACCESSORIES

3

INDEX

COLLET CHUCKS

COLLET CHUCKS

COLLET CHUCKS

CLAMPING RANGE: ø.010"-.787" (ø.25-20mm)

CLAMPING RANGE: ø.018"-.317" (ø.45-8.05mm) OVERVIEW X 18

CLAMPING RANGE: ø.010"-1.000" (ø.25-25.4mm) OVERVIEW X 19

MAX 25,000 RPM

MAX 40,000 RPM

MAX 50,000 RPM

OVERVIEW X 24

NEW BABY CHUCK ST SHANK ........................................ 278 N/C LATHE ....................................... 290

MEGA MICRO CHUCK BCV SHANK ....................................... 58 BBT SHANK ..................................... 108 HSK SHANK ....................... 170/212/221 BIG CAPTO SHANK .......................... 234 ST SHANK ........................................ 276 N/C LATHE ....................................... 287

MEGA NEW BABY CHUCK BCV SHANK ....................................... 59 BBT SHANK ..................................... 110 HSK SHANK .............................. 172/214 BIG CAPTO TYPE .............................. 236

COLLET CHUCKS

COLLET CHUCKS

MILLING CHUCKS

CLAMPING RANGE: ø.125"-.500" (ø3-12mm)

OVERVIEW X 22 CLAMPING RANGE: ø.625"-1.500" (ø16-50mm)

CLAMPING RANGE: ø.075"-.787" (ø1.9-20mm)

MAX 40,000 RPM

MAX 30,000 RPM

MAX 35,000 RPM

OVERVIEW X 20

OVERVIEW X 21

MEGA DOUBLE POWER CHUCK BCV SHANK ....................................... 63 BBT SHANK ....................................... 48 HSK SHANK .............................. 180/224 BIG CAPTO SHANK .......................... 244

MEGA E CHUCK BCV SHANK ....................................... 62 BBT SHANK ..................................... 116 HSK SHANK .............................. 178/223 BIG CAPTO SHANK .......................... 242

MEGA ER GRIP BCV SHANK ....................................... 61 BBT SHANK ..................................... 114 HSK SHANK ..................................... 176 BIG CAPTO TYPE .............................. 240 CKB SHANK ..................................... 265 ST SHANK ........................................ 288

MILLING CHUCKS

HYDRAULIC CHUCKS

MILLING CHUCKS

OVERVIEW X 26 CLAMPING RANGE: ø.125"-1.250" (ø3-32mm)

OVERVIEW X 25 CLAMPING RANGE: ø.500"-1.500" (ø16-42mm)

OVERVIEW X 23 CLAMPING RANGE: ø.750"-1.250" (ø16-32mm)

NEWHi-POWER MILLING CHUCK BCV SHANK ....................................... 66 BBT/BT SHANK ................................ 122 HSK SHANK ..................................... 182 BIG CAPTO SHANK .......................... 247 CKB SHANK ..................................... 266 ST SHANK ........................................ 280

MEGA PERFECT GRIP BCV SHANK ....................................... 65 BBT SHANK ..................................... 120 HSK SHANK ..................................... 181

HYDRAULIC CHUCK BCV SHANK ....................................... 68 BBT SHANK ..................................... 124 HSK SHANK ....................... 184/216/225 BIG CAPTO SHANK .......................... 248 ST SHANK ........................................ 281

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INDEX

BASIC ARBORS

BASIC ARBORS

BASIC ARBORS

CLAMPING RANGE: ø.250"-1.250" (ø4-20mm)

OVERVIEW X 37

SHRINK FIT HOLDERS BCV SHANK ....................................... 71 BBT SHANK ..................................... 132 HSK SHANK .............................. 188/218 BIG CAPTO SHANK .......................... 250 ST SHANK ........................................ 282

SHELL/FACE/END MILL BCV SHANK ....................................... 72 BBT/BT SHANK ................................ 134 HSK SHANK .............................. 191/226 BIG CAPTO SHANK .......................... 251 CKB SHANK ..................................... 262

SMART DAMPER FACE MILL ARBOR TYPE FMH BCV SHANK ....................................... 77 BBT SHANK ..................................... 139 HSK SHANK ..................................... 194 TURNING BORING BAR ST SHANK ........................................ 294

TAP HOLDERS

MODULAR HOLDERS

ANGLE HEADS

OVERVIEW X 28

MEGA SYNCHRO TAPPING HOLDER

OVERVIEW X 30

OVERVIEW X 40

CK SHANKS/BIG CAPTO/ABS BCV/CV SHANK ............................ 80-85 BBT/BT SHANK ................................ 142 HSK SHANK ....................... 198/219/227 BIG CAPTO SHANK .......................... 257 ST SHANK ........................................ 286

ANGLE HEAD BCV SHANK ....................................... 86 BBT SHANK ..................................... 148 HSK SHANK ..................................... 200

BCV SHANK ....................................... 78 BBT/BT SHANK ................................ 141 HSK SHANK ..................................... 196 BIG CAPTO SHANK .......................... 256 CKB SHANK ..................................... 267 ST SHANK ........................................ 285 N/C LATHE ....................................... 285

SPEED INCREASERS

SPEED INCREASERS

COOLANT INDUCERS

OVERVIEW X 43

OVERVIEW X 42

OVERVIEW X 44

Hi-JET HOLDER CV SHANK ........................................ 100 BBT/BT SHANK ................................ 162

AIR POWER SPINDLE BCV SHANK ....................................... 96 BBT SHANK .............................. 158/220 HSK SHANK ..................................... 210

HIGH SPINDLE BCV SHANK ....................................... 98 BBT SHANK ..................................... 160

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INDEX

MILLTURN TOOLING

TOOL HOLDER ACCESSORIES

TOOL HOLDER ACCESSORIES

PULLSTUD BOLT CV SHANK ........................................ 102 BT SHANK ........................................ 164 Only use Pullstud Bolts made by BIG. Accuracy is not guaranteed if poor-quality Pullstud Bolts are used. ! CAUTION

OVERVIEW X 38

OVERVIEW X 45

HIGH-PRECISION TEST BAR DYNA TEST CV SHANK ........................................ 103 BT SHANK .........................................166 HSK SHANK ..................................... 229 BIG CAPTO SHANK .......................... 259

BCV/CV SHANK ................................ 302 BBT/BT SHANK ................................ 306 HSK SHANK ..................................... 312 BIG CAPTO SHANK .......................... 318 ST SHANK ........................................ 294

TOOL HOLDER ACCESSORIES

TOOL HOLDER ACCESSORIES

TOOL HOLDER ACCESSORIES

BIG-PLUS CLEANER CV SHANK ........................................ 103 BT SHANK ........................................ 167

CLEANERS TK CLEANER .................................... 372 Į WIPER CLEANER ......................... 371 Į TAPER CLEANER ............337/351/358

ATC ARM POSITIONING TOOL ATC ALIGNMENT TOOL CV SHANK ........................................ 103 BT SHANK ........................................ 167

FINISH BORING

ROUGH & FINISH BORING

ROUGH BORING

OVERVIEW X 32

EWE ø.08"-6.00" (ø2-152mm) ...................... 416 ø1.61"-8.00" (ø41-203mm) .................. 455 EWN ø.016"-6.00" (ø0.4-152mm) ................. 417 ø.79"-8.00" (ø20-203mm) .................... 456 EWB ø.08"-1.97" (ø2-50mm) ........................ 417 ø1.26"-4.13" (ø32-105mm) .................. 466 ø3.94"-8.00" (ø100-203mm)................. 467

OVERVIEW X 31

MW ø.63"-.83" (ø16-21mm) .................... 395 SW ø.79"-8.00" (ø20-203mm) ................ 397 TWN ø.79"-8.00" (ø20-203mm) ................ 406

OVERVIEW X 36

SMART DAMPER CK BORING SYSTEM

SW SMART DAMPER ........................ 399 EWD/EWN SMART DAMPER ............ 459

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INDEX

LARGE DIAMETER BORING

DRILLS

INDEXABLE INSERTS

OVERVIEW X 34

INDEXABLE INSERT & SPADE DRILLS CKB SHANK ..................................... 530

INDEXABLE INSERTS ...................... 508

SERIES 318 ø7.87"-24.41" (ø200-620mm) ................ 479 ø24.41"-118.00" (620-3000mm) ............ 488

INDEXABLE END MILLS

EXCHANGEABLE HEAD MILLING TOOLS

FACE MILLS

OVERVIEW X 48

FULLCUT MILL BCV SHANK .............................. 542/550 BBT SHANK .............................. 543/551 HSK TYPE .................................. 545/553 BIG CAPTO SHANK .......................... 555 ST TYPE ..................................... 547/556

OVERVIEW X 51

FULLCUT MILL ARBOR TYPE .................................... 567

CONTACT GRIP BBT SHANK ..................................... 564 HSK SHANK ..................................... 565 BIG CAPTO SHANK .......................... 565

FACE MILLS

CHAMFER MILLS

CHAMFER MILLS

OVERVIEW X 50

OVERVIEW X 52

OVERVIEW X 53

SPEED FINISHER ..................... 568 SURFACE MILL .......................... 570

C-CUTTER MINI ST TYPE ............................................ 572 CKB TYPE ......................................... 576

C-CUTTER ST TYPE ............................................ 578 CKB TYPE ......................................... 579

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INDEX

CHAMFER MILLS

CHAMFER MILLS

RADIUS MILLS

OVERVIEW X 54

R-CUTTER ST TYPE ............................................ 586 CKB TYPE ......................................... 588 OVERVIEW X 54

C-CUTTER MICRO ST TYPE ............................................ 582 C-CENTERING CUTTER ST TYPE ............................................ 583

CENTER BOY ST TYPE ............................................ 584 C-CUTTER BOY ST TYPE ............................................ 585

BACK SPOT FACING TOOL

GROOVE MILLING TOOLS

MEASURING INSTRUMENTS

OVERVIEW X 46

OVERVIEW X 55

TOUCH PROBE & EDGE FINDER POINT MASTER SERIES .................. 596

BF-CUTTER ST TYPE ............................................ 590

GROOVE MILLING CUTTERS WITH CARBIDE INSERTS ST TYPE ............................................ 592 CK TYPE ........................................... 592 ARBOR TYPE .................................... 592

MEASURING INSTRUMENTS

MEASURING INSTRUMENTS

MEASURING INSTRUMENTS

OVERVIEW X 47

TOOL OFFSET SENSOR BASE MASTER ................................. 602 BASE MASTER GOLD ....................... 602 BASE MASTER RED ......................... 603 BASE MASTER MICRO ..................... 603 BASE MASTER MINI ........................ 604

OVERVIEW X 47

OVERVIEW X 46

TOOL OFFSET SENSOR TOOL MASTER ................................. 604

TOUCH PROBE & EDGE FINDER 3D MASTER RED .............................. 605 ACCU CENTER ................................. 605

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INDEX

MEASURING INSTRUMENTS

MEASURING INSTRUMENTS

MEASURING INSTRUMENTS

PRECISION MACHINE LEVEL LEVEL MASTER ............................... 611

OVERVIEW X 45

MEASURING DEVICE FOR PULLING FORCE

DIAL INDICATOR STANDS MP-TEC ........................................... 612

DYNA FORCE .................................... 607 DYNA LINE ....................................... 608 DYNA CONTACT ............................... 610

TOOL ASSEMBLY DEVICES

TOOL ASSEMBLY DEVICES

CLEANERS

TAPER & FLANGE CLEANERS SPINDLE CLEANER ......................... 621 HSK EXTERNAL TAPER CLEANER .... 621 Į TOOLING CLEANER ..................... 620

TOOL HOLDING DEVICES KOMBI GRIP ..................................... 616 ST LOCK ........................................... 616

TOOL HOLDING DEVICES TOOLPRO ......................................... 615 TOOLING MATE ................................ 617 TORQUE FIT ..................................... 619

CLEANERS

FLANGE THROUGH COOLANT We offer DIN69871/B flange through coolant upon request.

Oil Hole

70

P.C.D

TABLE CLEANING CHIPFAN .......................................... 622 T-SLOT CLEAN ................................. 623

Tool holders modified for flange through coolant must use proper pullstud to seal back flow of coolant into the spindle. ! CAUTION

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BIG-PLUS OVERVIEW

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BIG-PLUS ®

Conventional

FIT

Simultaneous Taper & Flange Fit 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

FIT

SPACE

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S P I N D L E S Y S T E M DUA L CON T AC T

Basic Concept The BIG-PLUS Spindle System is based on the most current available standards in ASME B5.50, JIS B6339 and DIN 69871. A conventional steep taper tool holder is supported on a reference diameter called the gauge line. On the contrary, a BIG-PLUS tool holder is supported on the flange face, which brings remarkable improvement to rigidity.

Increased Contact Diameter (Example of BT50) BIG-PLUS ®

CONVENTIONAL

Taper No.

Conventional

BIG-PLUS

SPACE

CV50 CV40 BT30

ø2.750 ø1.750 ø1.250

ø3.875 ø2.500 ø1.811

CONTACT

Perfect Interchangeability BIG-PLUS tool holders can be used on existing standard machine spindles. Existing standard tool holders can also be used on BIG-PLUS spindles. In this case however, simultaneous contact cannot be attained. Although other simultaneous contact systems require exclusive new accessories, BIG-PLUS tooling uses existing accessories such as a tool presetter and tool holder fixture as it is based on a conventional steep taper shank. Further, it is not necessary to modify tool magazines and ATC devices of existing machines.

Existing Accessories Utilized

BIG-PLUS ® SPINDLE + BIG-PLUS ® HOLDER CONTACT

CONVENTIONAL SPINDLE + BIG-PLUS ® HOLDER

Tool Presetter

BIG-PLUS ® Holder

CLEARANCE

Tooling Fixture

Conventional Holder

Tool Storage System

BIG-PLUS spindles have been adopted by licensed machine or spindle builders around the world under strictly controlled dimensions using BIG’s Master Gauge. In order to protect the spindle or prevent possible accident, only use tool holders with the BIG-PLUS trademark.

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BIG-PLUS OVERVIEW

Improvement of ATC Repeatability The BIG-PLUS Spindle System assures 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

10 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 No. of Times of ATC Machine: Horizontal (4 years old)

6"

ISO40

WITHIN 1 μm

Taper Contact (Conventional) Dual Contact (BIG-PLUS ® )

Test Bar (Zero Runout)

Pulling Force 800kg

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 holder flange face. This larger face contact, combined with the taper contact, works together to resist deflection. With less deflection, greater machining accuracy and superior finish can be achieved.

Strict Gauge Control

Comparison of Deflection

BT40

BT50

500

100

CONVENTIONAL

CONVENTIONAL

400

80

300

60

200

40

BIG-PLUS

CONVENTIONAL

100

BIG-PLUS ®

20

BIG-PLUS ®

0

Cutting Conditions Machine: 40 Taper (Horizontal Machining Center) Cutter: Face Mill ø5" (6 cutting edges) Work Material: A2017 Duralumin Cutting Depth: .094"

2

4

6

8

(kN)

F

0

1

2

3

4

(kN)

LOAD: F

F

LOAD: F

Deflection of a machine spindle is shown. A vertical machine was used for the test.

Deflection of a machine spindle is shown. A vertical machine was used for the test.

Strict Gauge Control BIG-PLUS spindles produced by the licensed machine or spindle builders are strictly controlled in dimensions by the BIG original Master Gauge. Only the BIG-PLUS trademarked tool holders can achieve the optimal performance fully and safely.

Gauges for Machine Spindle

Master Gauge

Measuring Device

Master Arbor

ACCUWAY, ADVANCED MACHINE , ALEX-TECH, AMS, ANCA, AONO GIKEN, ARES, ASA TECH, AWEA, BERG SPANNTECHNIK, BOST, BROTHER, CERI, CHEVALIER, CHUO-SEIKI, CITIZEN, COLGAR, D.S.TECHNOLOGIE, DAH LIH, DAIYA SEIKI, DAITO, DIXI, DMC, DMG MORI SEIKI AD, DMG MORI SEIKI CO.,LTD., DOOSAN, DYNOMAX , EGURO, ENSHU, FADAL, FAMOT, FANUC, FEMCO, FIRST, FIRST, FISCHER , FOREST-LINÉ, FPT, FRANZ KESSLER, FUJI SEIKI, GIDDINGS & LEWIS, GMN, GTI , HARDINGE, HARTFORD, HEYLIGENSTAEDT, HISION, HNK, HOMMA, HORKOS, HOWA, HST, HURCO, HWACHEON, IBAG, IBARMIA INNOVATEK, IKEGAI, INOUE KOSOKU KIKAI, JOBS, JOHNFORD, JTEKT, JUNGWOO M.S., JYOTI, KARATS, KASHIFUJI, KASWIN, KENTURN, KIRA, KITAMURA, KIWA, KMT, KOMATSU NTC, KONDIA, KOYO, KPTEC, KURAKI, LAZZATI, MAG, MAGNIX, MAKINO, MAKINO SEIKI, MANDELLI, MATSUURA, MAZAK, MECTRON, MILLTRONICS, MITSUBISHI, MITSUBOSHI KOGYO, MITSUI SEIKI, MOTOKUBO, MTE, MYL, N.S.S, NACHI, NAKAMURA, NEO, NICOLÀS CORREA, NIIGATA, NIPPON BEARING, NISHIJIMAX, NISSIN-MFG, NOMURA, NORTHLAND TOOL , NSK, NUMEN, O-M, OBATAKE, OHTORI, OKK, OKUMA, OMLAT, OMV, PAMA, PDS , PIETRO CARNAGHI, PMC, QUASER, REIDEN, ROKU ROKU, ROYAL, RS TEC, SAJO, SEMA, SEMPUCO, SETCO , SHAN RONG, SHODA, SHW, SKF , SKG, SKODA, SMEC, SNK, SODICK, SORALUCE, SPINDER, SPINTEC, SPINTRUE, SPS , STARRAGHECKERT, STUDER, SUFENG, SUGINO, SUNWOO, SUPERIOR SPINDLE SERVICE , SWIFT, TAJMAC-ZPS, TAKAMAZ KIKAI KOUGYOU, TAKISAWA, TANABE, THETA, TONGTAI, TOS KURIM, TOS VARNSDORF, TOSHIBA, TOYO SEIKI, TSUDAKOMA, TSUGAMI, UGINT, UTSUNOMIYA, VICTOR TAICHUNG, VTEC, VYU CHENG, WALDRICH COBURG, WELE, WIA, YAMASAKI GIKEN, YAMASHINA SEIKI, YASDA, YASUNAGA, YCM, YU HUNG, ZAYER (As of May 2020) BIG-PLUS Spindle System Machine Builders The BIG-PLUS Spindle System is offered by many of the world’s leading manufacturers of machining centers. Some of the machine and spindle builders who have produced BIG-PLUS spindles are as follows:

• Bold company names are North American licensed BIG-PLUS spindle rebuilders

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HSK OVERVIEW

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 HSK TYPE A/E/F HSK SIZES 25/32/40/50/63/80/100/125

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.

T

HSK Size

HSK Type

25

32

40

50

63 100

T

.043

.049

.076

.102

.137

.204

Drive Key Form HSK Shanks according to Form A are designed to carry out torque transmission by the round shaped key-way at the end of the taper. Because of the importance of this round shaped geometry, BIG provides finishing of this feature after heat treatment.

Important Tool Retention Feature Internal clamping of HSK tools is defined by the location of highly concentrated forces from the machine tool. Accuracy and position of this form will affect the rigidity, repeatability and precision of tool holders. BIG provides finish machining of this area after heat treatment.

Clamping Taper

AVAILABLE IN TURNING TOOLS HSK FORM T HSK-T63/T100 (ISO 12164-3)

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BIG CAPTO OVERVIEW

BIG CAPTO ISO 26623-1

A dual contact modular turning and rotating tool holder system that strengthens the performance of MTC’s. The BIG CAPTO modular tooling system offers better efficiency, material selection and heat treatment. * The trademark CAPTO is licensed from Sandvik Coromant

FIT

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 assures stable runout accuracy. Wider Range of Rotating BIG CAPTO Tooling than Any Other Provider

As a licensed manufacturer since 2002, BIG Daishowa through BIG KAISER offers a wider range of rotating BIG CAPTO tooling than any other provider. Extended reach collet chucks feature the world-class New Baby Collet system with less than 3 microns guaranteed accuracy at 4xD. Other solutions with BIG CAPTO include the MEGA ER GRIP, HYDRAULIC CHUCKS, the MEGA E CHUCK system, MEGA DOUBLE POWER CHUCKS for the highest rigidity while end milling, MEGA MICRO CHUCKS with the world’s smallest collet system for reaching into tight areas, and many more.

45º TILT STYLE TYPE S

S63 Basic Holder

S50 Basic Holder

90º RIGHT ANGLE STYLE TYPE F

Boring Bar

Square Tool Holder

F63 Basic Holder

For † Shank

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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 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 kept in stock.

Recess for the CKB Floating Cross-Bolt

CK Screw

CKB Floating Cross-Bolt

CKB CONNECTION: Highly Efficient And Easy To Handle The modular components are clamped with the lateral locking screw (CK-screw). The floating cross bolt is automatically centered in the trapezoid-shaped recesses in the mating part and ensures an absolutely uniform distribution of the torque forces. •Simple, efficient operation -no special equipment or tools needed •Maximum rigidity due to high preloading forces and large contact surfaces

•Precise cutting edge location even when using several adapters •High interchange accuracy, maximum radial change error is .0001"

CK Screw

A-A

CKB Floating Cross-Bolt

A

A

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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 lightweight 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. • Double connector coupling made of steel and aluminium extensions for the transmission of high torques • Weight reductions up to 50% and equal cutting performance, compared to tool combinations made of steel • Reduced weight allows easier handling and eliminates manual tool change in many cases • Max. rigidity of the tool connection due to high clamping force and expansion of the slotted tool connector • Vibration damping due to the use of different materials

Double Connector Coupling

A-A

Connector with Partial Slits

Extension Tube Aluminium

A

Compatibility CKN - CKB For compatibility reasons, the CKN shanks will be delivered with only one CK screw. For CKN assemblies, the remaining two CK screws will be supplied with the mating component having the male CKN connection.

Shank CKB/CKN Compatible

Double Connector Couplings

Extension Tubes Aluminium

15

MEGA CHUCK SERIES OVERVIEW

Wide variety of collets and chuck bodies to cover all high-speed ultra-precision machining applications.

Drive keyways are machined after heat treatment

Precision Ground and Balanced for High Speed Machining

MEGA CHUCKS are micro-mirror ground-finished on all surfaces to assure perfect concentricity for high speed machining. The drive keyway is machined after heat treatment.

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S P I N D L E S Y S T E M DUA L CON T AC T

Notch-Free Design MEGA NUT Prevents Vibration & Reduces Noise Vibration at high speeds is eliminated with the use of notch-free nuts, which offer superior balance and concentricity. This ideal nut design not only reduces whistling noise and splattering coolant, but also assures increased strength of the nut itself.

Notches for Wrench Application

Notches for Wrench Application

Smooth Tightening Operation by Ratchet Function

Easy & Firm Clamping by the MEGA WRENCH The unique MEGA WRENCH has a one-way clutch system with roller bearings and a ratchet function which is capable of safely and evenly applying force to the entire nut periphery.

A Variety of MEGA CHUCKS Available

MAX 40,000 RPM

MAX 30,000 RPM

MEGA MICRO CHUCK

MEGA NEW BABY CHUCK

MEGA ER GRIP

MEGA E CHUCK

MEGA DOUBLE POWER CHUCK

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COLLET CHUCK PROGRAM OVERVIEW

Taper Type

Collet Chuck Series

BCV BIG CAPTO 40 50 30 40 50 A40 A50 A63 A100 A125 E25 E32 E40 E50 F63 C4 C5 C6 C8 BBT HSK

MEGA3S MEGA4S MEGA6S MEGA8S MEGA6N MEGA8N MEGA10N MEGA13N MEGA16N MEGA20N MEGA25N MEGAER11 MEGAER16 MEGAER20 MEGAER25 MEGAER32 MEGA6E MEGA8E MEGA10E MEGA13E

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Tool Shank Range

MEGA3S (øD=.394) MEGA4S (øD=.472) MEGA6S (øD=.551) MEGA8S (øD=.709) MEGA6N (øD=.787) MEGA8N (øD=.984) MEGA10N (øD=1.181) MEGA13N (øD=1.387) MEGA16N (øD=1.654) MEGA20N (øD=1.811) MEGAER11 (øD=.787) MEGA25N (øD=2.44) MEGAER16 (øD=1.181) MEGAER20 (øD=1.378) MEGAER25 (øD=1.654) MEGAER32 (øD=1.969) MEGA6E (øD=.984) MEGA8E (øD=1.181) MEGA10E (øD=1.378) MEGA13E (øD=1.654)

17

MEGA MICRO CHUCK OVERVIEW

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CLAMPING RANGE: ø.018"-.317" (ø.45-8.05mm) Extremely slim design of body and nut provides superior balance and concentricity and is ideal for reaching into confined areas.

MAX 50,000 RPM

End Milling Drilling

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S P I N D L E S Y S T E M DUA L CON T AC T

PRECISION HIGH

Extremely Slim Design Nut ø.394"/.472"/.551"/.709" 3S/4S/6S/8S Type Slim design avoids interference. Ideal for small mold making combining speed and high precision capability.

High Concentricity MEGA MICRO COLLET 100% concentricity inspection.

Guaranteed runout within .00004" at the nose. Available for higher precision in steps of ø.004" (ø.1mm)

Strict Gauge Control

AT COLLET NOSE 3μm at end of test bar 1 μm

4d .00004" .00012"

NEW!

ø.394" FULL SCALE (3S TYPE)

Sealed Nut for Through- Tool Coolant (available for 6S & 8S only)

All BIG Collets are AA Grade and inspected twice for accuracy

A Variety of Interfaces for High Speed Machining

NEW!

20,000 rpm/1.5MPa

STRAIGHT SHANK TYPE

STRAIGHT TYPE

TAPER TYPE

MEGA MICRO COOLANT NUT (PAT. PENDING) For MEGA MICRO CHUCK 6S provides a more efficient coolant supply for micro cutting tools. Ideal design for high-speed micro machining up to ø6mm.

Up to 35% higher tool lifetime compared to standard nut

For Increased Versatility

Where Access is Restricted

For Increased Rigidity

Micro Collet

MEGA Micro Seal Nut

THROUGH TOOLS

NBCS

MEGA Wrench MEGA Torque Wrench

PG. 368 PG. 369

PG. 334

MEGA Micro Coolant Nut

JET THROUGH

PG. 336

18

MEGA NEW BABY CHUCK OVERVIEW

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CLAMPING RANGE: ø.010"-1.000" (ø.25mm-25.4mm) High speed design, offered in six different collet series sizes. Utilizes ultra precision New Baby Collets which guarantee a runout at the collet nose of less than .00004".

MAX 50,000 RPM

R

Reaming

End Milling Drilling

S P I N D L E S Y S T E M DUA L CON T AC T

Tool Extension Less Rigid !

Maximum Performance!

CAUTION!

Tool Extension Less Rigid !

Wide Range Available as Standard Ideal length and diameter of the holder is the key to precision machining. If selection is limited, an increased tool extension reduces performance.

CAUTION!

IDEAL CONDITION!

PRECISION HIGH

High Precision Collet, Close to Submicron NEW BABY COLLET

Two Way Coolant Sealed Collet Nut MEGA PERFECT SEAL •Standard NBC Collet is used •High dust resistance

THROUGH TOOLS

JET THROUGH

The NBC collet is 100% inspected to guarantee accuracy. Material, production, heat treatment... everything is selected for precision.

Strict Gauge Control

AT COLLET NOSE 3μm at end of test bar 1 μm

Tools with Holes

Tools without Holes

.00004"

.00012"

4d

All BIG Collets are AA Grade and inspected twice for accuracy

New Baby Collet

MEGA New Baby Nut

NBC (Standard)

Short Type

THROUGH TOOLS

PG. 344

PG. 338

MEGA Perfect Seal

MPS

NBC-E (For Endmill)

Adjusting Screw

PG. 346

JET THROUGH

PG. 340

Without PS Ring

MEGA New Baby Nut

PG. 368 PG. 369

THROUGH TOOLS

MEGA Wrench MEGA Torque Wrench

FONBC Coolant Collet

PG. 342

19

MEGA ER GRIP OVERVIEW

CLAMPING RANGE: ø.075"-.787" (ø1.9mm-20mm) High precision collet, nut and body that outperforms standard ER systems. Reliable and stable runout accuracy will also tremendously contribute to improving machining capability and cost reduction.

MAX 35,000 RPM

Reaming

End Milling Drilling

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S P I N D L E S Y S T E M DUA L CON T AC T

High Rigidity Body that Increases Collet Contact Area By increasing the contact length of the internal taper of chuck bodies, the undesired overhang of the collet is reduced. This modification of the standard improves 3 of the most important requirements for the collet chuck: rigidity, runout accuracy and clamping force. (Conventional DIN collets can also be used)

.00004"

.00012"

4d

ER Collet with the Best Runout Accuracy in the World Measurement standards in accordance with DIN 6499 and ISO 15488

Short

MEGA ER ® GRIP

DIN/ISO

Clamping Range ø.079 - ø.394 ø.394 - ø.787

MEGA ER ® GRIP

Class 1

Class 2

0.0004 0.0006

0.0006 0.0008

Within .00012

Current DIN Standard

Long

Variety Of Nut Selection Two type of ER nut as well as sealing nut offer the most suitable solution for your demand. These nut can also be used for conventional ER chuck models.

2-Way Coolant Supply Sealed nut MEGA PERFECT SEAL offers 2-coolant solutions.

THROUGH TOOLS

JET THROUGH

Tools with Holes

Tools without Holes

MEGA ER PERFECT SEAL

MEGA ER SOLID NUT

ER NUT

MEGA ER NUT

MEGA ER Nut

MERN PG. 355

MERSN MEGA ER Solid Nut

MEGA ER Collet

PG. 355

ER Nut

ERC

PG. 352

THROUGH TOOLS

ERN

Adjusting Screw

PG. 355

MEGA ER Perfect Seal

JET THROUGH

MERPS PG. 356

PG. 368

MEGA Wrench

Without PS Ring

20

MEGA E CHUCK OVERVIEW

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CLAMPING RANGE: ø.125"-.500" (ø3mm-12mm) Collet chuck designed exclusively for end milling up to ø.500" with high concentricity & rigidity. MAX 40,000 RPM

Reaming

End Milling

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S P I N D L E S Y S T E M DUA L CON T AC T

PRECISION HIGH

Sealed Collet Nut MEGA E PERFECT SEAL

High Concentricity MEGA E COLLET 100% concentricity inspection. Runout within 1μm at nose is guaranteed.

Sealed collet nut to supply coolant reliably through cutting tool. Ideal for burnishing drills and reamers due to the extended gripping length of the MEGA E CHUCK.

Guaranteed Max Runout

AT COLLET NOSE 3μm at end of test bar 1 μm

.00004" .00012" 4d

MAX COOLANT PRESSURE 1,000 PSI

All BIG Collets are AA Grade and inspected twice for accuracy

• Use only cutting tool shanks with the exact same diameter as the collet bore diameter.

High Gripping Strength Collet

Substantial and Tapered Body Design Thick body eliminates chatter and deflection. Tapered extension provides the rigidity to prevent vibration.

Extended Clamping Area

Gripping force is an important element for end milling with a collet chuck. The long gripping length of the collet in the

Bearings

Thick Body

Shallow Taper

Shallow Taper

Seals

MEGA E series provides a powerful gripping force. The shallower taper of the collet improves concentricity in order to achieve better surface finishes and longer cutting tool life.

MEGA E Nut

MEN

MEGA E Collet

MEC

THROUGH TOOLS

PG. 358

MEGA E Perfect Seal

Adjusting Screw

EPS

JET THROUGH

PG. 359

PG. 368 PG. 369

MEGA Wrench MEGA Torque Wrench

Without PS Ring

21

MEGA DOUBLE POWER CHUCK OVERVIEW

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CLAMPING RANGE: ø.625"-ø1.500" (ø16mm-50mm) High rigidity design for heavy cutting. Flange contacting nut and simultaneous taper & flange contact assure highest rigidity. MAX 30,000 RPM

End Milling

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S P I N D L E S Y S T E M DUA L CON T AC T

Stabilizing Contact Between Flange & Nut Provides Exceptional Rigidity The expanded contact diameter of the nut of the MEGA DOUBLE POWER CHUCK to the flange provides the highest rigidity as if the chuck and nut were one solid piece. This superior rigidity assures heavier duty machining without chatter.

BIG-PLUS

CONVENTIONAL

CONTACT

BBT50-MEGA32D-105 Radial d= .551” (14mm) Power= 20.3hp (15.2kW)

Other Manufacturer (L=90) Radial d= .374” (9.5mm) Power= 12.3hp (9.2kW)

Cutting Conditions Cutter: Coated Carbide End Mill ø32mm, 4-flutes

Work Material: A36 Steel (JIS SS400) Cutting Speed: 925 SFM (282 m/min) Spindle Speed: 2,800 RPM Feed Rate: 44 IPM (1,120 mm/min)

Released

Tightened

Secure Coolant Supply Two types are individually designed for the most

JET THROUGH

A Variety of Straight Collets Available

effective coolant supply. • Improved surface finish •Smoother chip evacuation •Extended tool life •Cooling & lubrication of tools

For jet through PJC collet

For through tools PSC collet

For through tools OCA collet

Type DS

C Collet

PG. 364

JET THROUGH

PJC Collet

PG. 362

THROUGH TOOLS

MEGA Wrench

PG. 368

PSC Collet

PG. 361

22

MEGA PERFECT GRIP OVERVIEW

CLAMPING RANGE: ø.750"-1.250" (ø16mm-32mm) Features 100% Security Against End Mill Slip or Pullout Under Any Torque Load! •A unique lock mechanism using a Key Grip prevents the slip and pullout of the tool during heavy cutting. •By simply using straight shank cutters with a Weldon flat, no special cutter is required. If your cutter doesn’t have a flat, adding your own flat according to the general Weldon standard allows its use in the MEGA PERFECT GRIP. MEGA PERFECT GRIP

EXCLUSIVE KEY GRIP

1

2

3

R

S P I N D L E S Y S T E M DUA L CON T AC T

Simple, Easy Handling with Secure Clamping 1. Place the exclusive Key Grip into the Weldon flat of the end mill shank.

2. Insert the end mill with the Key Grip in alignment with one of the three Key Grip grooves inside the milling chuck. 3. Rotate the end mill approximately 20º clockwise until the Key Grip stops securely against the stopper pin. 4. Finish clamping the tool until the clamping nut contacts the positive stop of the chuck body.

Non-Pullout Mechanism The Key Grip engages in the groove of the chuck body to ensure no tool pullout.

Complete Fit of Nut and Body Tightening the nut achieves dual contact between the nut and body for rigidity close to that of an integral cutter.

COMPLETE FIT

Exclusive Key Grip

Spring

Before Tightening

After Tightening

Non-Slip Mechanism The Key Grip maintains contact with the stopper pin to prevent any slip under high torque.

Flood Jet-Through Coolant The Key Grip grooves provide channels for high volume coolant to the cutter. Effective end milling of HRSA’s requires a high volume of coolant to the cutting edge to dissipate heat and aid in the removal of chips.

Key Grip

Stopper Pin

23

NEW BABY CHUCK OVERVIEW

NEW BABY CHUCK

CLAMPING RANGE: ø.010"-.787" (ø.25mm-20mm) High-precision collet chuck system with an accuracy of 1 micron at nose.

Reaming

Tapping

End Milling Drilling

PRECISION HIGH

High Precision Collet, Close to Submicron NEW BABY COLLET

The NBC collet is 100% inspected to guarantee accuracy. Material, production, heat treatment... everything is selected for precision.

Ensures High Accuracy The double effect of precision threads finished after heat treatment and the smooth tightening of the thrust balls without torsion on the collet achieves stable high-precision collet tightening. Furthermore, the mechanism acts to prevent the thrust ball from jumping out due to centrifugal force generated by high speed rotation, promising stable machining.

Strict Gauge Control

AT COLLET NOSE 3μm at end of test bar 1 μm

.00004"

.00012"

4d

Thrust Ball Bearings

All BIG Collets are AA Grade and inspected twice for accuracy

Coolant Through Tools (BPS) The sealing functionality of the PERFECT SEAL means that the higher the coolant pressure is, the tighter the PS Ring adheres to the tool shank, increasing the sealing effect. The secure sealing function allows coolant to be securely supplied to the tip for high-pressure machining in high-speed applications. A sealing nut is used with a standard collet.

Coolant Methods to Suit the Application BABY PERFECT SEAL A coolant nut with oil sealing functionality. Removing the internal PS Ring allows jet-through coolant supply.

MAX COOLANT PRESSURE 1,000 PSI

THROUGH TOOLS

JET THROUGH

TiN coating

Thrust ball

Seal (PS Ring)

NBC collet

The runout accuracy heavily affects finish quality and tool life. For holding an end mill, we recommend the use of an E Collet.

24

NEW Hi-POWER MILLING CHUCK OVERVIEW

CLAMPING RANGE: ø.500"-1.500" (ø12mm-42mm) Highly rigid chuck for resistance against chatter. Supports end milling with its heavy duty gripping force and high runout accuracy. NEW Hi-POWER MILLING CHUCK

End Milling

R

S P I N D L E S Y S T E M DUA L CON T AC T

Reliable Slit Design Ensures High Accuracy A unique BIG slit shape is adopted to achieve both the essential runout accuracy and gripping force which are the key elements of a milling chuck. Stable clamping is possible due to sufficient elastic deformation and the ability to remove oil film from the tool shank.

The Milling Chuck is Also Ideal as a Basic Holder Allows the reliable use of straight collets as well as boring bars, arbors such as face milling cutters.

SUPPORTS VARIOUS MACHINING

NEW Hi-POWER MILLING CHUCK

Stable Runout Accuracy Heavy Duty Gripping Force

Within .02

Tandem Roller Unit

Slits drain oil, preventing slip

Enhanced Shank Series BBT/BT SHANK

Consistent Elastic Deformation

BCV SHANK HSK SHANK BIG CAPTO SHANK

Reliable Slit Design Ensures High Accuracy CLAMPING DIAMETER: ø12mm & 1/2"

NEW!

Slim Nut Diameter of ø1.260" Reduces Interference

TOOL EDGE RUNOUT <2μm

Runout Adjustable RA Holder Simple Structure Allows for Easy Adjustment of Runout Accuracy! Compensates for increased runout of machine tool spindles caused by extended use. Simple structure allows for easy adjustment in the machine. •Consistent hole diameter • Improved surface roughness • Increased tool life

Diameter slimmer than collet chucks

JET THROUGH

HMC12J

NBS13

NBS16

ø1.260

ø1.654

ø1.378

25

HYDRAULIC CHUCK OVERVIEW

CLAMPING RANGE: ø.125"-1.250" (ø3mm-32mm) For high precision machining. Ideal tool holders for machining processes that require high accuracy such as drills, reamers, ball mills, end mills, diamond reamers and grinding tools.

MAX 40,000 RPM

Reaming

FinishMilling Drilling

R

S P I N D L E S Y S T E M DUA L CON T AC T

A Wide Variety of Clamping Diameters & Projections Available

Short Projection Length

Dual Oil Pressure Points

Runout Accuracy Less Than .00012" High precision runout accuracy less than .00012" at 4xD improves the workpiece surface finish and extends tool life.

Internal structure with increased accuracy and rigidity The integrated structure of the body and clamp sleeve gives greater rigidity and achieves better accuracy compared to the traditional two-part construction sealed with O-rings. 2-point tightening with dual hydraulic chambers and a short overhang area where the tool is not clamped give improved runout accuracy.

HIGH RUNOUT ACCURACY <3μm

4xD

Easy Clamping with 1 Wrench

The cutting tool can be clamped or unclamped easily and securely with just 1 wrench.

Allowable Shank Tolerance of Cutting Tools (h6)

REFERENCE INFORMATION “h6” INCH SERIES

REFERENCE INFORMATION “h6” METRIC SERIES

Cutting Tool Shank ø

Allowable Tolerance +0, -.00035 +0, -.00043 +0, -.0005

Cutting Tool Shank ø

Allowable Tolerance (μm)

1/8, 1/4, 3/8

3, 4, 6, 8, 10mm 12, 14, 16, 18mm

+0, -8μm +0, -11μm +0, -13μsm

1/2, 5/8

3/4, 1, 1 1/4

20, 25, 32mm

26

Meets Diverse Machining Applications! Abundant Lineup In Length And Clamping Diameter!

SUPER SLIM TYPE

MIN. BODY DIAMETER .551" Slim design eliminates interference. Ideal for high precision 5 axis machining.

MAX 60,000 RPM

Cylindrical Shank Series High precision cylindrical shank hydraulic chuck suitable for solving interference problems.

HSK-E25/E32/E40/F63 Series Ultra-Compact and High Precision Hydraulic chuck suitable for small machining centers.

PREBALANCING HSK-E25 <.5G.MM

JET THROUGH TYPE

Jet Through Hole MIN. BODY DIAMETER .79" Securely supplies coolant or oil mist to the tool periphery. Delivers outstanding results with high accuracy finishing in 5-axis machines. MAX 35,000 RPM Coolant Hole at Nose Supplies Coolant

Jet Through Groove

Type 4, 6, 8, 10 & 12J

Type 16, 20, 25 & 32J

27

MEGA SYNCHRO TAPPING HOLDER OVERVIEW

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TAPPING RANGE: ANSI: NO.0-NPT1", JIS/DIN/ISO: M1-M36 Tool holder for rigid tapping compensates for synchronization errors during rigid tapping. Improves thread quality and tool life by reducing thrust loads caused by synchronization errors up to 90%. * Patent is licensed from EMUGE

R

Tapping

S P I N D L E S Y S T E M DUA L CON T AC T

54 Body Models and 276 Tap Holder Models are Available Large tap series achieves a maximum of NPT1". An extensive variety of bodies suitable for many spindle types. Short, middle & long tap holders are standardized to cover between No.6 and NPT1" (M2 and M36). The slim design avoids interference.

DRIVE KEY

Secure Drive The body and Tap Holder are fixed with a drive key in the rotation direction as well as the square of the tap.

Coolant Through Center Capability for All Models Coolant is supplied both through the tool and to the tool periphery simultaneously.

THROUGH TOOLS

JET THROUGH

Coolant is Supplied Through Both the Tool and Slits of the Tap Holder

Coolant is Supplied Through Slits of the Tap Holder

28

MEGA SYNCHRO TAPPING HOLDER OVERVIEW

BIG MEGA SYNCHRO tapping holder compensates for synchronization errors with any type of tap. Minimized thrust load to both the tap and workpiece improves thread quality and tap life.

Load To Tap

Time (sec.)

0

.2

.4

.6

.8

1.0

1.2

1.4

1.6

-90 -68 -45 -22 0 22

BIG MEGA SYNCHRO ®

Approx. 13.2 lbs

BIG Mega Synchro reduces load to approx. 13.2 lbs. This is less than 1/10th of the load compared to a collet chuck.

Spiral Tap AU:1/4-20, N=1,000 RPM

-180 -160 -135 -110

Approx. 165 lbs of reversal load is applied to a tap held with a collet chuck.

Spiral grooves on spiral tap cause loading in the reverse direction, similar to an end mill. * Measured by Kistler Dynamometer

Approx. 165 lbs Collet Chuck

forward

stop

reverse

Comparison of Surface Finish Tapping of exotic materials tends to cause a compressed burr on the thread surface. BIG MEGA SYNCHRO compensates for synchronization errors and minimizes the cutting load. Fine surface finish of threads is achieved.

Cutting Conditions Spiral Tap No.10-24 Material: 4130

COLLET CHUCK

BIG MEGA SYNCHRO ®

.0002"

PATENT # 9446463

MEGA MICRO NUT

MEGA MICRO COLLET

0

.0002"

MGT3

.0002"

For Small Tap Tapping Range: ANSI: No.0-No.6, JIS/DIN/ISO: M1-M3

.0002"

Dynamic Runout Accuracy Within .0002 " (5μm) Even at 5,000 RPM Plotted position of a test bar (at .630" distance on .157" diameter)

Eliminating synchronization errors and minimizing dynamic runout at high speeds provides stable thread quality and extended tool life. • BBT Shank • HSK Shank • Cylindrical Shank • N/C Lathe Tooling

29

CK BORING SYSTEM OVERVIEW

Supports various applications from rough to finish boring with a large assortment of boring heads and accessories. Secure contact using a single wrench. CK MODULAR BORING SYSTEM

Secure Contact Using a Single Wrench! The Simplest Modular Boring Clamping System

The CK modular system is a simple method for securely and powerfully clamping multiple components with a single wrench. Moreover, even if the same boring head is repeatedly attached and removed, the cutting edge position does not vary by 2 microns (.00008"). This accurate clamping allows boring diameter setup to be done with a boring head only, increasing the machine utilization and drastically reducing labor.

CK Set Screw

REPEATABLE ASSEMBLY & REMOVAL ” 3μm

Only Hex Wrench Required

30º

CKB Pin

Safe Structure at High Torque Adopts a proprietary CKB pin for high cutting torque. The CKB pin is of floating type which gives it good horizontal balance, dampening cutting torque and making it possible to withstand heavy duty torque.

Perfect Face Contact

Rapid Adaptation To Special Tools Modular system that can be used to assemble special tools with standard items, allowing flexible compatibility.

Reduction

Extension

Chamfering

30

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