Category: Boring Large Diameter

IMTS 2016 Review of New Stuff

9/28/2016

We got to spend a few days in Chicago to get a great preview of some of the newest products and innovations for the kind of machining we do on the West Coast.

We spent quite a bit of time visiting the manufacturer's whom we represent to learn all the details about how their new innovations can help you cut down cycle time and improve throughput in your shop.

We've picked out just a few of the great things we learned about at IMTS 2016 below.

Next Generation Tooling IMTS 2016 Blue Photon workholding

Chris & Rob learning how to be workholding hero's at the Blue Photon booth at IMTS 2016

There's some really informative videos on quite number of the products so be sure and give yourself some time to watch them.

5th Axis - Duece Vise

Machine double the parts. Maximize your machines work envelope with the compact footprint. Utilize as a single station fixed jaw vise or convert to a double station. The deuce is designed for all the ways your machine.

Use as a single or double station fixed jaw vise. Two vises for the price of one.

The small footprint allows for multiple units to be ganged together on vertical or horizontal machines.

BIG KAISER - EWD EVO Digital Head

EWD EVO digital boring head

BIG KAISER is continuing down the path of digital tooling innovation with the introduction of the EWD EVO, a digital boring head designed with a single goal in mind—making the life of an operator as easy as possible.

It will be synched with the new BIG KAISER smartphone and tablet app, which was developed to enhance user friendliness while assembling and running BIG KAISER boring tools.

Not only will you be able to read the cutting diameter change, but the app will also help operators determine optimal cutting parameters from their tool assemblies. The app will also log historical adjustments for all tools ever synched with it, a critical piece for shops joining the smart manufacturing movement.

Heimatec Offers Machine Brand-Specific Tooling

Heimatec Inc. spotlighted its complete line of live tools and showcased them at IMTS in a series of four new catalogs. Already offering the most complete line of live tools available in the industry, with over 40,000 designs in its database,

Heimatec offers machine brand-specific tooling including products for the following popular brands: Mori Seiki BMT 40 NZ/NZX 1500-2000; Mori Seiki BMT60, NL/NLX 1500-4000 MC/Y/SMC/SY; Tsugami BMT 65 M06 D/SD/SY, M08 D/SD/SY; and Miyano ABX 64 TH/TH2/TH3, BND 51 S/SY, BNJ 42 SY3, BNE 51 SY5, BNJ 51 SY3.

Heimatec sets the standard for the highest precision and most advanced technology in the machine tool accessory market. The company is acknowledged as a world leader in live tools, angle heads and multispindle drill heads. In addition to its standard tooling and machine brand specific line,

Heimatec also offers custom-designed tooling. Heimatec tooling experts work directly with customers to design solutions to suit specific requirements for all CNC lathes, helping to solve the most challenging applications in multiple markets served by the company, ranging from orthopedic devices to oil & gas drilling equipment.

Visiting the Heimatec booth at IMTS #NGT #2016 #Heimatec

A photo posted by Next Generation Tooling (@nextgentool) on Sep 14, 2016 at 1:32pm PDT

MA Ford - CDA Aluminum Coolant Drill

MA Ford has expanded the Cyclone high-performance drill line with the new CDA drill, which is designed specifically for cutting aluminum. The twin-fluted CDA features an enhanced double margin design and lower thrust point geometry for increased penetration rates.

Deeper flute depth improves chip evacuation. The drills’ point relief and edge protection are maximized also for machining nonferrous materials. Reduced cutting forces allow heavier feed rates and improved location when drilling through cross holes.

The TuffCut XR7 line of carbide end mills now includes the new series 180CB chipbreaker end mill. The new chipbreaker design ensures that swarf is broken into smaller regular-sized chips to aid evacuation and prevent workpiece damage while prolonging tool life by reducing recutting of chips.

This expansion in the Long and X-long lengths allows for higher feed rates and minimized cutting forces, resulting in straighter walls on long axial engagements.

MASA - F20M10 Cartridge

Check out the video! Matt Saccomanno discusses the Microconic Workholding system at IMTS 2016.

Masa Tool has developed the Microconic™ system specifically for holding workpieces from Ø0.15mm to 10mm (Ø0.006" to 0.390") in any machine that has a collet-type chuck.

The system consists of two major components: The Microconic™ cartridge, which fits into your CNC machine spindle replacing the standard 5C, TF20 or TF25 collets, and the Microconic™ collet, which fits in the Microconic™ cartridge.

The Microconic™ system has unsurpassed concentricity: Our manufacturing tolerance is 3µm (.0001") and we guarantee our cartridges to be within 5µm (0.0002") in production use in your machine.

The Microconic™ system works with either draw-type or push-type standard collet systems that are in any machine.

The Over-grip collet capabilities of Masa Microconic™ System, introduces a whole new world of time saving opportunities awaiting. Our Overgrip Collets open up to 4mm (0.157") diameter larger than the clamping diameter.

mPower - Spin Select

Read this section or just watch the video! The SpinSelect Multi-Pocket Selectable Tool Holder was created to increase productivity and consistency by decreasing downtime associated with tool and insert setups and changovers.

SpinSelect’s patented, unique design allows for quick indexing between its five pockets with a simple ¼ turn of a socket head cap screw.

Each pocket can house a different tool, allowing for quick changes between operations without having to requalify the tools.

It excels at cutting harder materials, as the pockets are 30% stronger than traditional shank tools, allowing more rigid tools to be loaded.

Designed for use on most lathes having a turret or tool post, SpinSelect™ offers significantly better throughput on machining tasks such as heavy roughing, harder material removal, and short runs. Machining operators have seen up to an 85% savings on changeover/setup times as SpinSelect creates a nearly continuous runtime with offline insert changes/reloading.

NTK - PD2 Super Micorgrain PCD Inserts

The high speed turning of aluminium alloys and non-ferrous materials has now been taken to a new level with the introduction of the NTK PD2 insert line. With exceptional edge sharpness and adhesion resistance, the new PD2 range of inserts are ideal for extending tool life and productivity on difficult to machine alloys.

The new PD2 grade has a PCD grain size smaller than 1micron, which gives the new grade unrivalled edge toughness with impressive wear resistance characteristics.

This super-micro grain PCD enables the end user to conduct machining at cutting speeds beyond 220m/min with depths of cut from 0.1 to 0.25mm on nylon, plastic, copper, brass, epoxy and other non-ferrous materials with performance on aerospace grade aluminium alloys being particularly impressive.

NTK's new PD2 Super Micorgrain PCD Inserts

Furthermore, the edge toughness and composition give the PD2 tool life and consistency that is unrivalled when conducting interrupted and continuous machining.

NTK PD2 PCD tipped Carbide Insert

The new PD2 is available as a positive insert with a CCMT, DCMT and TPMT geometry that provides a PCD cutting edge length of 2.3mm with the option of a 0.2 or 0.4mm corner radius. The various insert geometries and available with an insert thickness from 2.4 to 9.5mm.

Complementing the positive geometry inserts is a complete selection of negative type inserts for the PD2. The CNMX, DNMX and TNMX geometries have a cutting length of 3.4, 4.5 and 3mm respectively and all inserts have a 4.76mm thickness that promotes strength and rigidity. The three insert types are available with a corner radius of 0.4 or 0.8mm to prevent edge breakages and prolong tool life and consistency.

Both the positive and negative type single cutting edge inserts are available with a range of toolholder designations to suit all types of turning centre from the smaller sliding head centres through to heavy duty turning machines.

OSG - Exopro Aero Series for Composites

A variety of cutting tools exhibited included the new EXOPRO AERO end mill series for composites.

Ever dream of machining composites without delamination and tool life issues? Composites are constructed with layers of material that are prone to delamination. They are also known to be abrasive and could easily wear your tool down. If your tool loses its sharpness, the material gets pushed away instead of cut, producing uncut fibers. OSG’s EXOPRO® AERO-BNC routerovercomes these problems and even provides high feed roughing and a superior finish.

Reduced Delamination and Cutting Forces
The AERO-BNC router features OSG’s patented nick design and a high helix that breaks up the cutting edges.

By breaking up composites with many cutting edges, instead of one long cutting edge, the nicked router can significantly reduce cutting forces. The lower the cutting forces, the less chance there is for delaminations and uncut fibers.

Longer Tool Life
The AERO-BNC also features OSG’s patented diamond coating which has a maximum diamond grain size diameter of 2μm. This ensures our coating is super smooth. Unlike our competition, we manufacture all diamond products in-house using our grinding technique on our special carbide substrate. This patented diamond coating coupled with the AERO-BNC router’s thick core diameter and multiple flutes extends tool life significantly. Improved part finish and sharper cutting edges are also the end results of the diamond coating.

Versatility
The AERO-BNC is extremely versatile and can be applied in both thick and thin laminates. It is versatile enough to handle trimming, slotting and shoulder milling applications! It also can engage parts by plunging, ramping or helical entry and is available in various end cuts to enable you to find the right tool for your job.

Techniks - Hydraulic Holders

Techniks Hydraulic Chucks provide powerful, vibration-free cutting in all materials. Hydros are a good choice when you need T.I.R. of 0.0001" and high holding power.

Techniks hydro's are factory balanced to 25,000 RPM at G2.5, and the tapers are precision ground to AT3 specification.

Reduction sleeves provide fast tool changes and you can run a variety of shank sizes from 1/8" up to 5/8"

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When Boring gets painful is it time to go digital?

8/14/2013

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This article originally appeared in the May 2013 / Volume 65 / Issue 5 of Cutting Tool Engineering titled "Evolving toward digital" By Matt Tegelman, BIG Kaiser Precision Tooling Inc.

Boring tools with a digital readout aren’t the standard in U.S. shops, but their use is growing.Think about the number of digital equipment interfaces and interactions an operator has when machining.

Machine operators use keypads and computers to run tooling programs and measure parts with digital gages and coordinate measuring machines. By definition, CAD/CAM work is accomplished digitally. Machine tool controls have digital displays. On most tool presetters—even simple ones without a vision system—the readout is digital. Bore gages are digital, whether it’s an air gage or a three-point-contact gage. There are still a few old-timers who trot out ID micrometers once in awhile, but most measurement devices are digital for speed and accuracy.

Digital has become the common language in metalworking and machining. The primary advantage of digital is its precision. There’s nothing subjective about a numerical reading. And this advantage has made its way to the boring head, where it is has been established technology for 10 years but is still far from being universally used.

As such, digital boring heads bridge the technology gap between digital measuring technology and existing tooling systems by adding a digital readout (DRO) to clearly show incremental diameter changes. So when an operator measures a bore and finds it undersized by 0.0004 " on the DRO of his measurement device, he simply has to zero the boring headreadout and adjust the diameter until the digital display reads “+0.0004 ".”

For the tightest-tolerance operations, one comparative drawback with analog systems is the frequency of human error—especially when the dial divisions are 0.0005 " on diameter. In addition, vernier markings complicate the adjustment procedure when it is necessary to split the divisions even finer. At that point, operators aren’t just moving from one division to another; they are forced to keep track of two different sets of markings to make fine adjustments, which can be confusing.

Of course, an operator could misread the number of zeros on a digital boring head, turning 0.0005 " into 0.005 ". But that error happens less frequently than an error caused when adjusting to a dial marking on a head that doesn’t have a DRO.

Kaiser’s new Series 112 EWD 2-54 precision-finish boring head has a built-in digital display that allows operators to make adjustments on the fly. The digital unit uses accessories from the Kaiser EWN 2-50XL Series, accommodates through-coolant and can be operated at a maximum spindle speed of 20,000 rpm.

Still Kicking

Analog readout technology isn’t dead because it’s still highly effective for the majority of low- to medium-level tolerance operations. Few shops have yet to make the switch to digital boring across the board, and it will be a long time before more do so on a regular basis. Digital boring heads cost 60 to 80 percent more than their analog counterparts.

That said, as old boring heads need replacement and more operators become accustomed to the advantages of digital boring adjustments, there eventually will be a turning point in some operations where it makes sense to go all digital. This change won’t happen just because it’s the direction of the industry.

Kaiser’s Series 310 EWD boring head’s measurement system shows precise linear movement of the tool carrier, permitting diameter adjustments of 0.00005 " (0.001mm).

Digital Advantages
Digital boring heads are, quite simply, easier to work with than analog heads. For tight tolerances, the ability to display actual cutting edge movement means operators don’t have to constantly check for accuracy for fear of backlash. Cartridge screw adjustment as a function of turning a dial screw or ring until a specific mark lines up is very accurate and still viable. But if boring heads aren’t properly maintained, operators can experience backlash.

Backlash is slop between the adjustment input and the tool carrier output. An operator rotating an adjustment ring or turning a dial on a worn or abused analog boring head may not notice any diameter change of the cutting edge on a tool presetter—even after moving several clicks or dial marks.

While the presetter is essential for initial setup, boring often requires a test-cut-and-adjustment procedure, which is most accurately completed while the tool is in the spindle. Heads with backlash make operators wary of adjusting tools in the machine spindle, which costs time and possibly accuracy if the boring bar does not sit in the presetter spindle exactly the same way as it does in the machine tool.

A digital system isn’t concerned with the input mechanism itself; rather, it measures the tool carrier travel directly, so an operator always has access to the true digital diameter readout. It doesn’t measure where the scale ring or dial says the cartridge should be—the real distance is on display.

Don’t Sacrifice PerformanceIf a shop is considering moving from analog to digital boring tools, the best conversions are those that can be accomplished without having to replace any accessories—simple one-for-one boring head trade-offs. Still, ask questions to ensure this is the case with your shop. Users can defeat the purpose of digital ease of use if the head isn’t a 1:1 replacement and additional programming or tinkering is necessary when converting to digital.

For instance, Kaiser’s 112 EWD, 310 EWD and 318 EWD digital boring heads are otherwise identical to their analog predecessors. They have the same boring ranges, cutting parameters and through-coolant capabilities, so an operator can swap an analog for a digital model with little or no reprogramming. All three series use the same accessories, such as boring bars and insert holders, as their nondigital counterparts.

Digital boring gives operators more confidence in their adjustments. It’s faster, too. Trying to make an adjustment of 0.004 " or 0.005 " on diameter when counting little dial divisions on a head, compared to seeing that value on a digital display, is a lot simpler and easier.

The return on investment from digital boring comes not only from time savings when making adjustments on the spindle, but also in the accuracy that prevents poor adjustments and resulting scrap. Shops producing high-end, tight-tolerance parts have expressed the most interest so far in digital boring.

Digital has become the true common language in metalworking and machining—a fact that will, sooner or later, influence boring tool selection, according to BIG Kaiser.

Despite the obvious advantages of digital, the technology isn’t yet for everyone. But as manufacturing and technology continue to become more and more entrenched in the digital realm, there will be a tipping point after which digital boring is the norm. Some shops will just be ahead of the curve. CTE

About the Author: Matt Tegelman is the Kaiser product manager for BIG Kaiser Precision Tooling Inc., Hoffman Estates, Ill. For more information about the company’s boring tools and other products, call (888) TOOL-PRO or visit www.bigkaiser.com.

Digital boring heads from Big Kaiser were designed to be a simple 1:1 match to their analog predecessors - same boring ranges, cutting parameters, and through-tool coolant capabilities - so an operator can swap an analog for a digital model with little or no reprogramming. Just like your cell phone or computer, it won't be long until you wonder how you ever lived without a digital interface.

Make the leap to digital technology.

WHY DIGITAL?

LCD display shows precise linear movement of tool carrier in both directions
IP 69K seal rating — highest possible
.00005"/ø or .001mm/ø setting accuracy
ø.016"-118.15"
Through-tool coolant supply
Reduces correction time & human error

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318: New Large Diameter Boring system from Big Kaiser

7/20/2011

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BIG Kaiser has introduced the new, large diameter Kaiser 318 Series—a complete tooling system supporting a variety of aluminum and steel components optimized for twin cutter rough boring, precision finish boring and precision OD turning operations.

The new series features a standard boring range of Ø7.87"-13.39" for ISO40/HSK-A63 tapers, and Ø7.87"-24.41 for ISO50/HSK-A100 and larger tapers.

Special components allow the system to extend up to Ø118". The mounting flanges feature Kaiser's new CKN modular connection with a three-screw interface, developed for high torque transmission with light weight tools.

The system supports spindle speeds of up to 6,600 SFM thanks to safe and secure "pinned to fit" light weight aluminum mounting components. The high strength aluminum components are hard coated to protect against wear and corrosion, and all assemblies deliver high pressure coolant through the tools to cutting edges.

"The 318 series features aluminum extension slides that allow for diameter and length setting adjustments without a tool presetter," says Jack Burley, BIG Kaiser vice president of sales and engineering. "The simplicity of this system virtually eliminates operator error during assembly and promotes safety during operation."

BIG Kaiser Precision Tooling is a leader in high precision tooling systems and solutions. With brands including Kaiser, BIG Daishowa, Speroni, Unilock, Sphinx and more, BIG Kaiser's line is focused on extreme accuracy and repeatability.

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IMTS 2016 Review of New Stuff

5th Axis - Duece Vise

BIG KAISER - EWD EVO Digital Head

Heimatec Offers Machine Brand-Specific Tooling

MA Ford - CDA Aluminum Coolant Drill

MASA - F20M10 Cartridge

mPower - Spin Select

NTK - PD2 Super Micorgrain PCD Inserts

OSG - Exopro Aero Series for Composites

Techniks - Hydraulic Holders

When Boring gets painful is it time to go digital?

318: New Large Diameter Boring system from Big Kaiser

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​NTK - PD2 Super Micorgrain PCD Inserts

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Find us on Instagram @nextgentool

NTK - PD2 Super Micorgrain PCD Inserts