The BIG KAISER Product Guide is an overview of our total tooling solutions, the product portfolio comprises of more than 20,000 precision tools such as fine/rough boring heads, tool holders cutting tools, measuring equipment, and workholding which adhere to the highest quality standards.
BIG KAISER PRODUCT GUIDE — TOTAL TOOLING SOLUTIONS 2018-2019
WHO WE ARE
Founded in 1948, BIG KAISER designs, manufactures and markets premium high-precision tooling systems and solutions for the automotive, military, aerospace, energy, and micro-technology industries. The global company has facilities in Japan, Switzerland, Germany and the USA. The product portfolio comprises of more than 20,000 precision tools, which adhere to the highest quality standards. A trend-setter in precision, performance, innovation and service, BIG KAISER is proud of its in-house production of digital displays and direct electronic measuring systems for digital precision boring heads to ensure absolute setting accuracy and eliminate operating errors. BIG KAISER is part of the family owned BIG Daishowa Group with 900 employees worldwide.
BIG KAISER — USA
BIG KAISER — SWITZERLAND
BIG DAISHOWA — JAPAN
UNITED STATES BIG KAISER est. in 1990 SWITZERLAND BIG KAISER est. in 1948
JAPAN BIG DAISHOWA est. in 1967 GERMANY BIG KAISER est. in 2010
BIG KAISER — GERMANY
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INDEX
OVERVIEW BIG-PLUS, BIG CAPTO, HSK, CK/CKB/CKN....................................... 4-5 TOOL HOLDERS COLLET CHUCKS MEGA MICRO CHUCK, MEGA NEW BABY CHUCK, MEGA ER GRIP, MEGA E CHUCK ........................................................ 6-7 MILLING CHUCKS MEGA DOUBLE POWER CHUCK, MEGA PERFECT GRIP, NEW Hi-POWER MILLING CHUCK ..................................................... 8-9 HYDRAULIC CHUCKS ......................................................................9 MILLING HOLDERS SHRINK FIT HOLDER, SHELL/FACE MILL HOLDER, END MILL HOLDER, SMART DAMPER MILLING .................................. 10 MODULAR HOLDERS CKB SHANKS, BIG CAPTO SHANK, ABS SHANK ................................ 10 TAP HOLDERS MEGA SYNCHRO TAPPING HOLDER .................................................... 11 ANGLE HEADS & COOLANT INDUCERS AG90, AGU, Hi-JET HOLDER ................................................................ 12 SPEED INCREASES AIR POWER SPINDLE, HIGH SPINDLE . ...............................................13 TURNING TOOLS DUAL CONTACT MODULAR SYSTEMS TYPE S/F/BASIC ARBORS, N/C LATHE & SMART DAMPER TURNING . ..................................... 14-15 BORING TOOLS BORING SYSTEMS & DRILLS CK ROUGH BORING SYSTEM, CK FINISH BORING SYSTEM, TURNING ADAPTERS, O.D TURNING, CKB HEAVY METAL SOLID BARS .................................................... 16-19
CUTTING TOOLS INDEXABLE END MILLS & FACE MILLS FULLCUT MILL, SPEED FINISHER, SURFACE MILL ............................ 20 MILLS & BACK COUNTERBORING TOOLS C-CUTTER, C-CUTTER MINI, C-CUTTER MICRO, C-CUTTER BOY, R-CUTTER, BF-CUTTER, CENTER BOY, C-CENTERING CUTTER, GROOVING TOOLS ................................... 21-22 SPHINX DRILLS MICRO DRILLS, HIGH PERFORMANCE DRILLS, TWIST DRILLS, DRILL REAMERS, MICRO END MILLS ........................ 23 WORKHOLDING UNILOCK WORKHOLDING ROUND CHUCKS, RECTANGULAR CHUCKS, PRE-ASSEMBLED CHUCKS, MINERAL CAST SYSTEMS, AUTOMATION CHUCKS, STABILIZER SYSTEM, MULTI-AXIS SYSTEMS, UNIFLEX SYSTEM ...................................... 24-25 MEASURING INSTRUMENTS SPERONI MEASURING MACHINES STP ESSENTIA, STP MAGIS, STP FUTURA, STP FUTURA AUTOSHRINK, SPERONI CONTROL SOFTWARE........................................................... 26 MEASURING INSTRUMENTS BASE MASTER, TOOL MASTER, LATHE MASTER, ACCU CENTER, 3D MASTER RED, CENTERING TOOL, POINT MASTER, DIAL INDICATOR STANDS, DYNA TEST, DYNA LINE, DYNA CONTACT, DYNA FORCE, ATC ALIGNMENT TOOL, LEVEL MASTER ................. 27-29 ACCESSORIES TOOL ASSEMBLY DEVICES TOOL PRO, KOMBI GRIP, TOOLING MATE, ST LOCK, TORQUE FIT, COLLET EJECTOR ........................................................... 30 CLEANERS TOOLING CLEANERS, SPINDLE CLEANERS, T-SLOT CLEAN, CHIPFAN CHIP & COOLANT FAN, BIG-PLUS CLEANER, ..................... 31
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DUAL CONTACT TOOL HOLDERS OVERVIEW
BIG-PLUS TOOLING SYSTEM
BIG CAPTO TOOLING SYSTEM, ISO 26623-1
HSK TOOLING SYSTEM Dual contact system featuring a 1:10 taper in accordance to ISO & DIN standards. Since HSK is a hollow taper shank, the material plays a critical role for optimum performance. We use carefully selected high grade alloy steels, and all critical features are finished after heat treatment.
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 • Elimination of Z-axial movement at high speeds
Polygonal tapered dual contact system (1:20 taper) where the face and taper of a machine spindle and tool holder are in contact. This modular tooling system strengthens the performance of milling and turning operations for MTCs. * The trademark Capto is licensed from Sandvik Coromant
FIT
The BIG-PLUS Spindle System is based on the most current available standards in ASME B5.50, JIS B6339 and DIN 69871. BIG-PLUS surpasses all other spindle concepts while offering interchangeability with existing machines and tool holders.
Wide Variety A wide variety of rotary tool holders such as the high precision Mega Chuck series are available, as well as a modular turning tool system for MTCs. Excellent Repeatability High repeatability is achieved due to the perfect fit of the polygon taper to drive spindle rotation. Excellent Runout Accuracy The combination of a self-centering 1:20 taper and the long taper edge ensures stable runout accuracy.
R
BIG-PLUS ®
Conventional
S P I N D L E S Y S T E M DUAL CONTACT
FIT
A Variety of HSK Types and Sizes Form A: 32/40/50/63/80/100/125 Form E: 25/32/40/50/63 Form F: 63/80
FIT
SPACE
BIG-PLUS Spindle System Machine Builders
Prebalanced design for high speed
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, 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, 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, PIETRO CARNAGHI, PMC, QUASER, REIDEN, ROKU ROKU, ROYAL, RS TEC, SAJO, SEMPUCO, SETCO, SHAN RONG, SHODA, SHW, SKG, SKODA, SMEC, SNK, SODICK, SORALUCE, SPINDER, SPINTEC, SPINTRUE, SPS, STARRAGHECKERT, STUDER, SUFENG, SUGINO, SUNWOO, SUPERIOR SPINDLE SERVICE, 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 June 2017)
Drive keys machined after heat treatment
Internal retention form machined after heat treatment
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CK MODULAR TOOLING SYSTEM OVERVIEW
Through high precision modular technology, a wide range of selections are available for rough and finish boring — from micro to large diameter. The modular system also includes tooling solutions for O.D. turning, drilling, milling, tapping and grooving.
The modular system allows you to assemble standard items to optimize performance for various requirements. Standard Components for Custom Applications
Chamfering Tool
Reduction
Extension
AVAILABLE IN CV40/45/50, BCV40/50, BT30/40/50, BBT30/40/50, HSK-A25/32/40/50/63/80/100/125, HSK-E25/32/40/50/63, HSK-F63/80M & C5/6/8 Extensions Reductions Shanks
CK/CKB Connections
CK Connection Consists of a cylindrical male pilot and female receptacle. The connection is made by means of a radial locking screw with a 15 degree taper. CKB Connection Derived from the CK connection without loss of all technical and dimensional features or interchangeability and ease of maintenance. The CKB connection is equipped with a floating drive pin which engages on both sides into respective pockets in the mating part.
Perfect Face Contact
CKN Connection
Shanks
Extensions
The CKN connection is almost 100% compatible with CKB and is based on a 3-screw connection with double connector steel couplings and aluminium tubes as extensions, allowing the highest torque transmission. By tightening the 3 screws, the slotted male connection expands and gives additional rigidity to the tool connection.
AVAILABLE IN CV40/50, BCV40/50, BT40/50, BBT40/50 & HSK-A63/100
Boring Tool App
NEW!
Settings Set default language and units of measurement
Tool Tips Reminders pop-up to aid with tool assembly optimization
Tool Overview
Application Data Receive insert recommendation and operating parameters
Enhances user interface while assembling and running our boring tools. The app will help operators determine optimal cutting parameters and provide operating manual information. • Cutting data calculator • Calculator for adjusting tools • Quick access to operating manuals
Get application- specific cutting data
5
RPM
UP TO 6,600 SFM
COLLET CHUCKS MEGA CHUCK SERIES – Best Suited for High Speed Applications
MAX 30,000 RPM
MAX 10,000 RPM
ALL MEGA CHUCKS AVAILABLE IN BCV, BBT, HSK & BIG CAPTO
Mega Chucks are a multi-functional high speed holder series designed to optimize high speed and precise cutting with drills and end mills. All components, including body, collet, nut and clamping wrench are specifically designed for balanced high speeds.
MAX 45,000 RPM
MAX 40,000 RPM
MAX 16,000 RPM
R
S P I N D L E S Y S T E M DUAL CONTACT
MEGA MICRO CHUCK
MEGA NEW BABY CHUCK
Precision Ground and Balanced for High Speed Machining
MAX 50,000 RPM
MAX 20,000 RPM
Clamping Range: ø.010"-1.000" For drills, reamers, taps and finishing end mills.
Mega Chucks are micro mirror finished on all surfaces to ensure perfect concentricity for high speed machining. The Mega Chucks are then balanced with a high precision dynamic balancing machine. • Micro mirror ground finish on all surfaces • Balanced with a high precision dynamic balancing machine
MAX 80,000 RPM Also available in straight shank & N/C Lathe type. See Pg. 15
World’s highest precision & multi-purpose collet chuck system is well accepted and recognized by the market for its high speed application and its guaranteed 1 micron runout.
MAX 30,000 RPM
D
MAX 120,000 RPM
New size added to allow up to ø1" cutting tools!
NEW SIZE!
MAX 45,000 RPM
MAX 40,000 RPM
Clamping Range: ø.018"-.317" For micro drill & end mill applications. Super slim design with ø.394" nut prevents interference with workpieces and jigs. “Taper Type” features a super slim tapered design for added rigidity during micro end milling. MAX 35,000 RPM MEGA MICRO COLLET Wide coverage for small shanks is available with clamping intervals of ø.004" (ø.1mm). World’s Smallest Clamping Intervals MEGA MICRO SEALED & JET COOLANT NUT For Mega Micro 6S & 8S. Unique design increases sealing performance with higher coolant pressure to create a perfect seal. MAX 70,000 RPM
MAX 33,000 RPM
THROUGH TOOLS
JET THROUGH
MAX 50,000 RPM
MAX COOLANT PRESSURE 1,000 PSI
Drive keyway machined after heat treatment
MAX 80,000 RPM
With PS Ring
Without PS Ring
NEW!
MEGA PERFECT SEAL Unique design increases sealing performance with higher coolant pressure. Remove the PS Ring to supply coolant to the cutting tool periphery.
MAX 120,000 RPM
High Precision Collet
MAX 35,000 RPM
MAX 33,000 RPM NEW BABY COLLET Clamping Range: ø.010"-1.000" & ø.5-25.4mm
Compact in size, but excellent clamping force for small precision applications.
The world’s highest precision collet was developed based on BIG’s long experience and know-how, and each is inspected twice to guarantee the maximum runout tolerance permitted.
MAX 70,000 RPM
Wrenches
AT COLLET NOSE 3µm at end of test bar 1 µm
Guaranteed Max Runout
The Mega Wrench has a uniquely designed one-way clutch system with a roller bearing and ratchet function that is capable of safely and evenly applying force on the entire nut periphery.
.00004"
.00012"
4d
All BIG Collets are AA Grade and inspected twice for accuracy All BI ollets are AA Grade and inspected twice for accuracy
AVAILABLE IN DIGITAL
6
RPM
RPM
RPM
COLLET CHUCKS
MAX 120,000 RPM
MAX 50,000 RPM
MEGA E CHUCK
MEGA ER GRIP
MAX 35,000 RPM
MAX 33,000 RPM
MAX 80,000 RPM
Clamping Range: ø.075"-.787" For drills, reamers, taps and finishing end mills.
Clamping Range: ø.125"-.500" Exclusively for high speed finish end milling. The advanced tapered body technology enhances rigidity to prevent chatter and deflection with precision.
The total precision of our collet, nut and body when used together shatter the common standard of ER collet chucks. Incredibly low runout will provide dramatic payback by improving machining capability & reducing production costs. MAX 70,000 RPM
Also available in N/C Lathe type. See Pg. 15
MAX 120,000 RPM
MEGA ER PERFECT SEAL For two-way coolant supply.
THROUGH TOOLS JET THROUGH
MAX 35,000 RPM
MAX 33,000 RPM
Slit-through coolant with standard Mega E Nut
MAX 70,000 RPM
Thrust Ball Bearing
MEGA ER SOLID NUT Slot-free outer diameter increases rigidity of the nut. ER NUT Basic nut with surface treatment for friction reduction.
MEGA ER NUT A notch-free nut prevents vibration and noise. Steel balls in the thrust bearing are retained by a mechanism inside the nut designed for high speed operation. Mega Nut is the recommended nut to achieve high accuracy and clamping force.
MEGA E PERFECT SEAL Optional sealed collet nut for coolant through tools. Remove the internal PS Ring to supply coolant to the cutting tool periphery. However, by using the standard Mega E nut, coolant can still be directed to the cutting tool through slits in the collet, as seen above.
Best Runout Accuracy in The World ERC COLLET
Guaranteed Max Runout
AT COLLET NOSE 3µm at end of test bar 1 µm
.00004"
.00012"
Each ERC collet is inspected twice (0º and 180º) at four times diameter to guarantee the runout accuracy.
4d
Powerful Clamping Force
All BIG Collets are AA Grade and inspected twice for accuracy All BIG Collets are AA Grade and inspected twice for accuracy
Extended Clamping Area
MEGA E COLLET Exact sizes, shallow taper and extended clamping length enhances the
High Rigidity Body
High precision runout accuracy less than .00012" (3µm) at 4xD improves the workpiece surface finish and extends tool life. Repeatability has less than .00006" (1.5µm) of variance!
By increasing the contact length of the internal taper of chuck bodies, the undesired overhang of the collet is reduced. This modification of the current DIN standard improves 3 of the most important requirements a collet chuck: rigidity, runout accuracy & clamping force.
Seals
clamping and self-centering forces for stable performance.
Difference in Runout Accuracy
Shallow Taper
.0010
Bearings
.0008
AT COLLET NOSE 3µm at end of test bar 1 µm
Short
Competitor’s ER chuck
MEGA ER ® GRIP
.00004" .00012" 4d Guaranteed Max Runout
.0006
.0004
MEGA ER ®
.0002
All BIG Collets are AA Grade and inspected twice for accuracy All BIG Collets are AA Grade and inspected twice for accuracy
Current DIN Standard
Long
0
2
3
4
5
1
Number of Measurements
7
SFM
MILLING CHUCKS
UP TO 6,600 SFM
NEW HI-POWER MILLING CHUCK
MEGA DOUBLE POWER CHUCK
Clamping Range: ø.625"-1.500" (16-50mm) For heavy duty end milling. MAX 10,000 RPM Complete contact of nut and body achieves high rigidity, close to that of an integral tool to ensure heavy cutting without chatter. Notch free nut makes high speeds possible. MAX 16,000 RPM
Clamping Range: ø.500"-1.500" (12-42mm) For heavy duty end milling.
The thick wall body and high gripping force ensures high rigidity and stable performance. Fine and narrow slits in the body make the clamping part deform properly to ensure even and strong gripping force and stable runout. Now available in BIG-PLUS as standard. See PJC collets on Pg. 9 for reduction and coolant delivery options.
MAX 20,000 RPM
Powerful Clamping for Heavy Cutting
CONVENTIONAL MILLING CHUCKS
CONTACT
MAX 30,000 RPM
Thin wall
MAX 45,0 RPM
MAX 40,000 RPM
NEW!
Released
Tightened
HMCJ Type Clamping Range: Beginning at ø.500" (ø12mm)
Single roller
Uneven elastic deformation
Powerful Clamping Force Deflection test to compare with other manufacturer’s milling chuck proves that the Mega Double Power Chuck has achieved 1.4 times higher rigidity. MAX 50,000 RPM
Decreased runout accuracy and insufficient gripping force.
No escape route for oil film which causes processing failure. Remaining oil film reduces gripping power and may cause slip.
HMC12J
MGN13
MGN16
MAX 80,000 RPM
15 Stiffness (N/m)
0
5
10
1.4
HMC
BBT40-MEGA20D-75 MAX 120,000 RPM
Thick wall
1.0
Other manufacturer’s 40 taper milling chuck