Precision-Finish Boring Head for High-Speed Spindles
Big Kaiser’s EWN 04-7 series of precision-finish boring heads are designed for use on micro-milling machines with high-speed spindles such as HSK-E25, E32 or E40.

Presetter Builds on Previous Models
The Speroni Futura tool presetter combines the features of previous models, taking its look and design from the smaller Magis model while offering the repeatability and robustness of the Esperia line, the company says.

World’s Smallest Boring Head?
With a diameter range of 0.016” to 0.276”, this boring head is well-suited for a variety of micromachining applications.

Precision-Finish Boring Head for Micro-Milling
The Big Kaiser EWN 04-7 series precision-finish boring head is designed for micro-milling machining with high speed spindles such as HSK-E25, E32 or E40.

Worth Three Machines
A shop that closely tracks machining performance says its new horizontal machining center delivers productivity comparable to three verticals.

The Big Step Up
A small shop added two new machines, each of which is more advanced than any of the previous machine tools the company has used. One of the co-owners committed to the work of bringing both of these machines fully into service. Here is the shop’s experience so far.

Innocent Until Proven Guilty
When something goes wrong with a machining process, it can be easy to misplace blame.

Racetrack Success Begins in the Shop
Andretti Autosport says a chuck and a tool presetter from BIG Kaiser Precision Tooling have been critical in manufacturing parts for its redesigned 2012 IndyCar lineup.

Andretti Autosport Finds Shared DNA, Culture with BIG Kaiser
The Mega E collet chuck and a Speroni presetter are among the products the race team cites as critical to success in the shop and on the track.

When Reshoring Really Happens
Bob’s Design Engineering illustrates how a shop that used to be organized for short-run work transformed its process for ongoing production.

Rigidity Proves Key to Precision Boring
Thanks to a more rigid boring head from Big Kaiser Precision Tooling, a new machine that had been relegated to only roughing jobs is now holding the tight true-position and diameter tolerances that this shop’s customers have come to expect.

The Humble Pull Stud
I’ve said that the toolholder is the least appreciated element in many milling processes, but the pull stud (or retention knob) is perhaps the least appreciated component of the toolholder.

BIG Kaiser Embraces “New Media” Tools
While the main attractions at BIG Kaiser’s Booth W-1600 are aimed at maximizing efficiency on the shop floor, the company has also embraced technology that helps attendees make the most of their time on the show floor.

Video: Understanding Toolholders
The toolholder is arguably the least appreciated element in a system for successful milling on a machining center. Watch a presentation for optimizing the interface between the cutting tool and the spindle.

Boring Head and Damper to be Displayed
The Kaiser series 310 EWD precision finish digital boring head from Big Kaiser features absolute setting accuracy shown on a built-in digital display.

BIG Kaiser Tooling System Can Handle Large Workpieces
Designed for machines such as Makino’s T2 and T4 models, BIG Kaiser’s HSK-A125 tooling system is capable of tackling large-scale titanium and other workpieces on large tables, making it especially suited for use in the aerospace industry.

Twin-Cutter Boring System Offers Flexibility
BIG Kaiser’s 319 SW series twin-cutter, rough boring system enables users to switch between balanced and stepped cutting by reversing the insert holders.

ER Collet Chuck System Offers Rigidity, Balance
With a runout accuracy of 0.00012" (3 microns) at 5×D, BIG Kaiser’s Mega ER Grip is designed to increase clamping force, concentricity, rigidity and balance at high spindle speeds.

High Precision, Lightweight Boring Tool System
BIG Kaiser’s large-diameter Kaiser 318 series complete tooling system supports a variety of aluminum and steel components optimized for twin cutter rough boring, precision finish boring and precision OD turning operations.

Hydraulic Chuck Promotes Smooth, Stable Cutting
BIG Kaiser’s high-precision hydraulic chuck is designed for clamping straight-shank tools with diameters ranging from ¼" to 1¼" and 6 to 32 mm.

Last Glance at IMTS 2010
It would be impossible to cover all of the key exhibitors at IMTS 2010—even if every booth got merely a quick glance. However, the editors of MMS did get glimpses of some interesting technologies exhibited at the show...

Presetting Process Cuts Scrap, Rework
Aerospace manufacturer Fokker Aerospace Group relies on Speroni’s STP46 tool measuring and presetting machine to ensure that step drills used to cut and chamfer holes on aircraft flap skins are within tolerance and set to the proper length. This machine and custom procedures developed by Speroni enables the aerospace manufacturer to avoid cost and downtime resulting from reworking or scrapping these large parts.

Systems for Precision Boring and More
The large-diameter 318 series is a tooling system designed for twin cutter rough boring, precision finish boring and precision OD turning operations for the diameter range of 7.87" to 24.41".

Expanded Modular Tooling System
BIG Kaiser Precision Tooling has expanded the Kaiser KAB modular tooling system capabilities to include the rigid, high-feed C-Cutter Mini chamfer mill line from BIG Daishowa Seiki.  

Timing Is(n’t) Everything
There’s no good or bad timing. Moving ahead is the thing.

BIG Kaiser Grand Opening

Modular Connection for Large Boring Tools
The CKN modular connection for large boring tools features a three-screw interface, providing high clamping forces for maximum torque transmission.

In-House Repair Center Saves Time, Money
Cutting tool manufacturer BIG Kaiser (Hoffman Estates, Illinois) says its in-house repair center can fix tools at a fraction of the cost and time involved in shipping tools abroad for repair.

HSK Turning Tools For Mill-Turns
BIG Kaiser Precision Tooling has expanded its turning tool line to include HSK-T63 tools for mill-turn centers (MTCs).

Synchronous Tapping Holder And More
 The company says its synchronous tapping holder, the Mega Synchro, compensates for synchronization error during rigid tapping by reducing the thrust load to both the tap and workpiece.

Big Kaiser Opens New HQ
Cutting tool manufacturer Big Kaiser Precision Tooling has opened a new corporate headquarters in Hoffman Estates, Illinois.

CKN Modular System For Large Boring
 BIG Kaiser Precision Tooling’s CKN modular connection utilizes both steel and lightweight aluminum components.

Big Kaiser Opens New HQ
Cutting tool manufacturer BIG Kaiser Precision Tooling has opened a new corporate headquarters in Hoffman Estates, Illinois.

Capto Modular Tooling Catalog
BIG Kaiser’s 44-page, full-color catalog details the complete line of BIG Coromant Capto C5/C6/C8 turning and rotating tooling. The expanded Capto product line includes Mega Micro and shrink-fit holders; extended gage lengths for the Mega N and Mega E series; and more than 500 rotating and turning tools that are available from stock.

Balance Rings, Radial Adjustable Toolholders
BIG Kaiser offers two balancing accessories for the 112 series EWN precision boring heads. Balance rings and radial adjustable holders allow compensation for imbalance in tool assemblies for diameters ranging from 0.

Gage Lengths Extended
BIG-Plus CAT50 shell mill adapters from BIG Kaiser are now available in standard 8", 10" and 12" gage lengths on 1" and 1½" pilot diameters and 4" and 6" lengths on a 1¼" pilot diameter. For increased rigidity, the 10" and 12" lengths with the 1" pilot diameter feature a tapered body.

MMS Online Adds Cutting Tool Experts
Struggling with a challenge related to cutting tools? Get answers to your questions on tools and related equipment from this team.

Extended Gage Lengths For Toolholder Line
BIG Kaiser has expanded its BIG-Plus line of toolholders by introducing extended gage lengths for its shell mill adapters and shrink-fit toolholders. The line’s CAT50 shell mill adapters are available standard in 8", 10" and 12" gage lengths on 1" and 1½" pilot diameters and 4" and 6" lengths on a 1¼" pilot diameter.

Reducing Thrust Loads During Rigid Tapping
Some amount of synchronization error is inevitable with rigid tapping. By allowing just a slight amount of axial movement to compensate for synchronous errors, this tapping holder is said to reduce thrust load by as much as 90 percent.

Big Kaiser Breaks Ground on New Headquarters
Cutting tool manufacturer Big Kaiser Precision Tooling recently began construction of a new corporate headquarters in Hoffman Estates, Illinois. The new facility, which will be nearly three times larger than the company’s current headquarters, will be used for administration, application engineering, inventory, testing and training.

Expanded Drill Series Offers Consistent Process Reliability
BIG Kaiser Precision Tooling has expanded its Phoenix drill series, which is part of the Sphinx product line. The solid carbide Phoenix drill is said to offer more productivity than conventional solid carbide counterparts.

How Do You Machine a 30:1 Hole in Stainless Without the Drill Wandering?
An expert in micromachining says one answer is to check various aspects of the drilling process. Another answer is not to use a drill at all.

Tapping Holder Improves Thread Quality And Tap Life
 The Mega Synchro tapping holder compensates for synchronization error during rigid tapping by reducing the thrust load to both the tap and workpiece, improving thread quality and tap life. This is facilitated through a mechanism that absorbs the pitch difference between the tap and synchronous spindle. Capable of supplying coolant through slits to the tap periphery, the holder is available in various lengths and spindle interfaces to suit any company’s needs.

Too Small To Touch
Hummingbird takes on machining work that is too small for most shops to handle. In fact, Hummingbird tries not to handle it either. To accurately machine the tiniest parts, this shop relies on processes that are as hands-off as possible.

Boring Head Features Fine-Adjusting Resolution
The EWB-UP ultra precision finish boring head is part of a series of boring tools with fine-adjusting resolution (0. 00005" on diameter for inch-graduated heads and 0. 001-mm steps of diameter corrections).

Tooling Manufacturer Celebrates 60th Anniversary
In celebration of its 60th anniversary, Heinz Kaiser AG recently hosted a company tour and formal reception at its Rumlang, Switzerland facility. Founded in 1948 by Heinz Kaiser, the company specializes in the development and manufacturing of high-precision modular tooling systems. Attendees toured the Kaiser facility in small groups, giving them the chance to observe the high precision and quality control checks that go into producing Kaiser tools, the company says.

Ultra Precision Finish Boring Head

Digital Boring Heads Offer 1-Micron Diameter Adjustments

Solid Carbide Micro Drills

No Need For Speed
In this shop, high speed machining makes sense at 4,000 rpm. While the disciplines the shop put in place made a new 15,000-rpm profiler dramatically more productive, high speed machining would have remained valuable even if the new machine never came. Acoording to a co-owner of this shop, high speed machining has no need for speed.

Milling Chuck Pumps Up Productivity
Rigid toolholding offers a platform for productivity on this pump manufacturer's mill-turn center.

Drills Designed To Cut Hard Materials

Presetter Spindles Provide Precision, Repeatability

A Practical Guide To Presetters
Tool measurement devices help shops save time, control runout and improve tool management.

Drills Feature Tool Connection With High Clamping Force

Alternate Workholding Method Fits New Machining Strategy
Increased demand for armor plating components led this shop to completely revamp its machining technique. Rather than machining individual workpieces, the shop produces multiple components nested in an aluminum plate. A custom vacuum workholding system plays a significant role in this new strategy.

Boosting Machine Spindle Speed For Micromachining Applications
Small-diameter micromachining tools require very high rpm for sufficient cutting speed and material removal rates. This air spindle provides 80,000 rpm and an untethered compressed air interface to allow automatic changeovers using the machine's ATC.

Chamfer Rings Add Features To Boring Heads

The Real Cost Of Runout
A seemingly small amount of runout can still be too large for the tool. Reduce this runout, and tool life or productivity may dramatically increase.

Holders Offer Adjustable Chamfering Angle

Toolholder System For Multitasking Series

High Speed Boring Of Small Diameters

Auto Shrink Presetters

An Indexable Insert
The solid end mill is a machine shop staple. Its positive cutting edge removes metal by slicing through the material, rather than by scraping.

T-Slot Protector

Standard Toolholders For Older, Discontinued Machine Tools

New Clamping Chuck Offered With Workholding System

Tooling Reduces 21 Minute Job To 9 Minutes
Shop leadership was looking for a way to reduce the time it took to complete a very difficult boring job. The job took 21 minutes per part to complete with multiple roughing and finishing processes. It required 10 minutes of hone time.

The Role Of Balance In High Speed Finish Boring
Precision boring is particularly vulnerable to unbalance, but not every high speed boring application demands a balanceable tool.

Setting Tools Makes Small Shop Sense
Some people think tool presetting can be justified only in large operations. This Arizona shop shows how it makes sense almost anywhere.

Wisconsin Manufacturer Solves Boring Problem With Extensions
V&L Tool, Inc., located in a Milwaukee suburb, had to solve one of its toughest boring problems before beginning the manufacturing of a new hydraulic jack.