Jack Burley
Finish Boring of Ductile Cast Iron (FCD500)
Cutting Conditions Machine: HMC (BBT50) BIG-PLUS ® Boring Dia: ø2.677" Depth of Hole: 16" (L/D=6:1) Insert Nose Radius: R .016"
Cutting Speed (SFM)
Result
Tool Holder
500
80
165 325
Outperforms competitor’s holder by 6X higher productivity. Superior surface finish and better tool life due to the increased cutting speed.
Competitor (w/o damping system)
Feed Rate: .008"/rev. Depth of Cut: .012"/ø
Built-in damping mechanism SMART DAMPER
= Vibration
= Acceptable
= Excellent Surface Finish
Since its added rigidity provides several other advantages in addition to vibration reduction, dual contact has also proliferated across tooling companies’ product lines as well. A word of caution, however: not all dual contact systems are created equal. BIG-PLUS is the only true dual contact system for 7:24 taper systems. Tolerance testing has repeatedly shown that unlicensed 7:24 taper tooling billed as “dual contact” does not hold up when compared to authentic BIG-PLUS equipment. Only our parent company, BIG Daishowa Seiki (Osaka, Japan), owns the master gages that ensure the proper relationship between the taper gage line and tool flange. And only licensed and properly trained tooling suppliers can produce and sell these tools
components and fasteners, then filled with a composite structure of mineral particles and epoxy resin. Also notable is how the finished composite structure is produced without heat to better preserve the integrity of the precision machined surfaces and clamping components. Mineral particles make up about 90 percent of the added weight, with the remaining being resin and curing agents. The added composite structure has an excellent density-to-weight ratio of 2.3 kg/dm3, translating to application solutions that are about 50 percent lighter than alternatives and allow for higher output and better quality. That brings us to a tooling-specific solution: When it comes to vibration and tooling, the buzzword you’ll often hear is “overhang,” a condition that is also
with the BIG-PLUS trademark. We advise that you choose wisely and don’t discount the value of this technology if you’ve been unimpressed or, worse yet, burned by a knock-off system. Another area we specialize in where measures can be taken to combat vibration is how the part is held. No sandbags allowed. Our recommended weapon of choice is a mineral cast workholding solution. The advanced materials and methods used to produce this type of fixturing remove weight and introduce damping qualities into the foundation that exists between the machine table and part. The result is attenuation rates that are six to 10 times better than standard gray cast iron. How is this accomplished? The assemblies
are precision machined and filled with ground positioning
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