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Masa Introduces the new F20M10 Cartridge for Swiss Lathes at #IMTS 2016

7/26/2016

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Masa Tool has just introduced the F20M10 Cartridge as the latest expansion of  the Microconic™ system . The System was developed specifically for holding workpieces from Ø0.15mm to 10mm (Ø0.006" to 0.390") in any machine that has a collet-type chuck.
The push type F20 Cartridge replaces the standard TF20 collet in your CNC spindle. This enables you to use the Microconic collets to achieve concentricity guaranteed to be within 5µm (0.0002") in production use.

The system consists of two major components: The Microconic™ cartridge, replaces the standard TF20 collets and  fits into your CNC machine with no modifications to the spindle required.  The second component to the system is the  Microconic™ collets which have capacities of 0,22mm - 10,00mm ( 0.0086" - 0.3949") and -Over-Grip collets which can open up to 4mm over the chucking diameter and run within 5 µm/.0002" TIR
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F20M10 Microconic Cartridge
The new F20M10 Cartridge is compatible with spindles that accept Schaublin F20,  Southwick & Meister TF20, KEB (MasWerks) MC20,  Hardinge TF20 / 4611 collets to name but a few.
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F20M10 Cartridge. Standard single piece construction extended nose
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F20M10 Cartridge with a UM10 Collet installed
The Microconic™ system and F20M10 Cartridge 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 
F20M10 Cartridge fits the  following models of Swiss Machines as well as several others.
  • Citizen Models:  A16, C16, K16, M16.
  • Maier Models:  ML-16A/16B, ML-16C/16D.
  • Star Models:  ECAS 12/16, JNC16, KJR16B, RNC16 & II, RNC16B & II, SA12, SA16/16R, SB16/16S, SE12, SE16, SH12, SH16, SI 12/12C, SNC15DX, SR16/16R, SST16 STM32, SV12, VNC12.
  • Tornos Models: DECO 2000 13, Elector16, ENC16, ENC162, ENC164.
  • Traub Models: TNL-16G
  • Tsugami Models: NMP16II, NP16/16 II, NT12, NT16 II/16 III, 600, 600P.​ 
  • Tornos CAM Models: M15, R16
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F20M10 Cartridge with standard TF20 Pull Type closing system

Micrograd™ Face Dial Wrench permits accurate clamping pressure adjustment

​As with all Microconic Cartridges, the F20M10 comes standard wit a Micrograd™ Face Dial Wrench.  The Micrograd wrench  gives you the ability to to set your collet clamping pressure. 

The Micrograd™ Face dial Wrench provides a method of precisely setting clamping pressure on both the Microconic collets and an Microconic overgrip collets .  It can be adjusted in metric increments of 0,02mm and imperial increments of .001"
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Micrograd Face Dial Wrench to to set clamping pressure
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Is BIG-PLUS An International Standard?

3/9/2016

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More and more, we are asked this fairly simple question from shops who want to purchase BIG-PLUS® dual contact tooling from sources other than us. One would certainly think that this must be the situation, given that more than 100 of the world’s top selling machine tool builders have adopted the BIG-PLUS spindle system as their own standard. The truthful answer to anyone who asks is that this system has not been standardized by any governing body such as ISO, DIN, JIS, or ASME.
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This comparison of licensed BIG-PLUS vs. unlicensed BIG-PLUS tooling shows how little or no taper contact in the unlicensed tool holder can allow “float” in the spindle taper with no positive radial location, causing large cutter runout and immediate fretting corrosion on that spindle face that can severely damage the spindle.
BIG Daishowa, the original developer of this system and a major reason that it has been so widely accepted throughout the world, still holds all of the proprietary information and, more importantly, the grand master gages that are used for reproducing spindles and tooling. Access to this information and gaging is well protected by BIG and is only provided to those companies who acquire a license agreement, mostly to protect the integrity of the system, which uses very close tolerances in order to function at its designed performance level.
​
The popularity of BIG-PLUS has surged over the past ten years as many shops have tried the system and have witnessed for themselves the huge benefits in higher performance and accuracy over standardized taper contact tooling systems, such as CAT or BT. Other dual contact systems, such as HSK, have also seen a rise in popularity for similar reasons, but perhaps not with all of the same benefits of BIG-PLUS. Unfortunately, all of this increased popularity and demand has been accompanied by a surge in unlicensed copies to the market that offer all kinds of promises and prices never seen before.
BUYER BEWARE
I cannot fault a shop for purchasing cheap dual contact tooling after being told by their supplier that it will work just as good as the originals for half the price. After all, human nature wants to find the best offer at the best price – that sort of deal is capitalism at its best. As consumers, we are all confronted with choices every day about buying similar products that do similar functions from a wide range of suppliers and costs. For me personally, I usually decide to buy cheap only when I know the product will be used one time and then thrown away. On all other purchases, I’m in it for the long haul and willing to pay higher prices. At the end of the day, I want to be confident I made the right choice for the long term, and I’m willing to pay more for my peace of mind.
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Master gages for tooling are quite common. Generally all of them are traceable to a known master to compare the accuracy for rate of taper for production of tool holders, such as CAT or BT. ISO dual contact systems such as HSK rely on the use of a grand master gage that all other master gages are produced to, thereby guaranteeing that all HSK tool holders are the same everywhere in the world. Our company decided to find out how the world’s leading suppliers of HSK tool holders compared to the tolerances of the ISO standard. After acquiring more than 30 HSK-A63 taper tools from our competitors from all over the world and making a detailed quality inspection of the taper itself, we found that 50 percent of the samples were not in tolerance.
Perhaps the developers of HSK were overly critical of the functional limits and tolerances for the standard, given that 50 percent of most tools in use today are out of tolerance. In my opinion, this could be possible based on the very thin cross section of HSK tapers that allows for tool holders to expand elastically more than it was designed for.

On the opposite side however, we have BIG-PLUS that relies on elastic deformation of the spindle, not the tool holder, therefore requiring a much stricter control of tolerances, even in comparison to HSK. This means anyone who is in the market for BIG-PLUS ‘dual contact tooling’ should also consider this simple statement:

​Only a licensed supplier of BIG-PLUS has master gages that are traceable to the BIG grand master gages and have the dimensions and tolerances provided to do it right. Everyone else is guessing and using a sample BIG-PLUS tool holder as their own master gage – a practice that any quality expert will advise against.
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Unless all of the tools are marked “BIG-PLUS® Spindle System-License BIG DAISHOWA SEIKI,” the use of tooling not made by BIG Daishowa or its licensees may result in unsatisfactory performance and/or damage to very expensive spindles.
What are the consequences to a poorly researched choice in BIG-PLUS tooling? Unless all of the tools are marked “BIG-PLUS® Spindle System-License BIG DAISHOWA SEIKI,” the use of tooling not made by BIG Daishowa or its licensees may result in unsatisfactory performance and/or damage to very expensive spindles. Conditions producing such unsatisfactory performance include:
  • Distance between flange face and gauge line diameter more than specification-little or no face contact occurs; tool holders provide only taper contact and no benefit of BIG-PLUS.
  • Distance between flange face and gauge line diameter less than specification-face contact only; tool holders “float” in spindle taper with no positive radial location. Large cutter runout and fretting corrosion on spindle face occurs immediately. Severe spindle damage will occur.
  • Gauge line diameter less than specification; face contact only with minimal or no taper contact. Severe spindle damage can occur.
  • Gauge line diameter more than specification; taper contact only and no benefits of BIG-PLUS.
BIG Daishowa Seiki and its North American subsidiary, BIG KAISER, are manufacturers and distributors of original, licensed BIG-PLUS tooling. For a complete list of all licensed spindle and tool holder companies authorized for the production of BIG-PLUS, please contact us and remember: accept no substitutes.
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Jack Burley
Jack Burley is the vice president of sales and engineering at BIG KAISER Precision Tooling Inc., 2600 Huntington Boulevard, Hoffman Estates, IL 60192, 847-228-4011, Fax: 847-228-0881, jack.burley@us.bigkaiser.com, www.bigkaiser.com.

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Taking the weight off of Tombstone Fixturing

10/16/2013

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One of the problems we see often (but not many people ask us about) is the process of actually loading a new fixture on the side of a tombstone in a horizontal CNC milling machine. Hoisting up the fixture and aligning dowel pins can become quite a chore and really increase set-up time and changeover time on the machine.  And we all know that time is money. If the machine is waiting for parts to cut then you're not making money in your shop!

Many shops get a blank t-column or tombstone fixture and then machine in dowel pin locations to mount dedicated sub-plates on to them.  That's simple enough to do but it can be cumbersome to navigate and mount the sub-plate to the column.
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The mPwer docking station retrofit might be something to consider.  You can machine in the receiver V's and mount the tangs into your sub plate. 

This allows you to drop the sub-plate into the docking station receivers and its positioned about .015" below center of your mounting bolt holes.  It's a much easier and simpler way to get your sub-plates mounted!

The cost of this docking system will easily pay for itself in reduced manpower time alone within the first several uses. 

It's also available all ModLoc tooling columns.

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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.
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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.
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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.
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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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Flexible 5-Axis Workholding Solutions Keep Spindles Running

6/19/2013

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BIG Kaiser brings flexible workholding to 5-axis machine tables by surrounding Unilock zero-point quick-change receivers with a grid pattern. The benefits of 5-axis machines are greatest when workholding is based on the size and shape of the workpiece instead of the limitations of the table interface. By providing multiple workholding opportunities, Unilock users quickly integrate most workholding products and keep their machine spindles up and running.
“BIG Kaiser’s unique approach to 5-axis workholding seamlessly fits into existing workholding solutions while providing the increased flexibility of Unilock zero-point solutions. Our clients match workholding to the workpiece and maximize the capabilities of their 5-axis machine tools,” says Gerard Vacio, Product Specialist, Workholding Systems. “We can also provide specific solutions for your dedicated production requirements. We interface virtually any workholding product that fits in the machine.”
Unilock quick-change components can be directly attached to workpieces that need to be held without any side restrictions or attached to frequently used workholding devices for rapid changeover. Operators need the flexibility to run both today’s products, and the products they have yet to encounter. Combining grid plate functionality opens up opportunities for BIG Kaiser users.

This multi-axis Unilock solution does not obstruct access to the tops and sides of the part for true 5-sided machining.
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These quick change solutions are available for 5-axis tables as well as 4th and 5th axis tables on 3-axis machining centers. When quick turnaround for workpiece and workholding changeover is vital to maintaining spindle uptime, BIG Kaiser delivers customer-specific solutions, as well as off the shelf products. Solutions can be delivered ready-out-of-the-box, or production drawings can be supplied to clients who choose to build their own table interfaces.
Providing BIG Kaiser with a drawing of your machine table (or the make and model number) is all it takes to get started. Clients can also request production drawings or use third party suppliers. BIG Kaiser offers several flexible machine table interfaces, some of which can be delivered as turnkey solutions. We can pull workpieces down onto the table to maximize the available envelope, or elevate workpieces for complete 5-sided access.
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Increasing CNC Production throughput with Tool Presetting

2/13/2013

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All too often, shops invest hundreds of thousands of dollars in a new machining center to increase production, when they could accomplish the same thing with existing machinery at a fraction of the cost. Many machines cut metal less than 50% of the time during working hours— even less in a flexible manufacturing environment where part runs are generally short. For the rest of the time, these machines sit idle while their operators are setting up tools in the spindle. Instead of purchasing an additional CNC machining center, a shop can invest in equipment that allows it to set up tools outside the machine, so the spindle can make chips while the next tool is being adjusted and prepared.
If this shop used tool presetting equipment, then the operators wouldn’t have to waste valuable spindle time touching off tools or making trial cuts. Instead, they could preset tools for the next operation or reset tools after changing inserts while the machine continues to run. As a bonus, the operators could preset cutters with adjustable pockets for a balanced chipload, rather than setting these indexable tools on the machining center, which is very time-consuming.

Many shops have found that routine use of offline tool presetting equipment significantly reduces spindle downtime and keeps their machine tools producing quality components. Offline adjustment of boring bar length and diameter can reduce tool-changeover time at the machine spindle from 15 minutes to less than 1 minute. On CNC lathes, similar reductions in setup times are routinely achieved. With tools that require a length-only setup, shops can realize a reduction in setup time from 5 minutes to less than 1 minute per tool.
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Presetters measure the cutting edges of your tools to assure they precisely match job specifications and are ready to be used in the machine. Adjustments that could take up to 15 minutes when made on your machine can be made offline in less than a minute on a presetter, while your machine continues cutting.

The result - better parts, longer tool life, and less spindle downtime.
  • Offline tool set-up dramatically reduces spindle downtime on your machine
  • Precise and repeatable measurements deliver extreme tolerances
  • Eliminate test cuts with FIRST PART PRECISION
  • Reduce operator error
  • Increase efficiency - store and analyze tool data for lean use and maximum tool life
For more information about presetting tools contact us or Big Kaiser and we'll set up a demonstration!
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    Our NEWS  blog section is written by several different people. Sometimes, it from our team here at Next Generation Tooling & at other times it's by one of the manufacturer's we represent.

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Next Generation Tooling
10240 Cavalletti Drive
Sacramento CA 95829
916.765.4227
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Suite B
Lodi, CA 95240
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22343 La Palma Avenue
​Suite 126
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