MACH 2024: ITC to present new Big Kaiser Innovations

The new Big Kaiser MW rough boring heads
The new Big Kaiser MW rough boring heads

Tamworth cutting tool manufacturer Industrial Tooling Corporation (ITC) will be exhibiting at the MACH exhibition in April with a wide range of new cutting tool solutions on show.

On Stand 432 in Hall 20, the company will present its latest product lines as well as cutting tool solutions from Widia, Kemmler, Karnasch, Bass and Big Kaiser.

Renowned as a leader in precision tooling and holemaking applications, Big Kaiser has introduced a plethora of new products over the last 12 months – all of which will be on the stand at MACH.

From its portfolio of bore machining products will be the expansion of the Big Kaiser EWN Monoblock range. Guaranteed to improve productivity and performance for end users, the system uses Big Kaiser’s Smart Damper technology that will reduce chatter and subsequently cycle times, delivering excellent machining accuracy and surface finish quality.

Big Kaiser hydraulic chuck for sliding head turning centres
Big Kaiser hydraulic chuck for sliding head turning centres

The EWN Monoblock fine boring heads have been expanded with the new CK1 and CK2 products that support the machining of diameters from 20 to 36mm and 25 to 47mm respectively. The full EWN monoblock family of products ranges from the smallest CK1 to the largest CK7 which now supports fine boring from 20mm to over 200mm diameter.

Also new from the Big Kaiser bore machining stable will be the new MW rough boring bars. Manufactured from carbide, the new boring bars deliver significantly improved precision levels when compared to steel alternatives by reducing vibration and chatter. 

Typically, cylindrical boring bars are manufactured from steel, and this has the disadvantage of creating considerable deflection and vibration during operation. By using carbide, which has four times the density of steel, flexing is decreased by a factor of more than 16 which significantly reduces vibration.

The reduction in deflection means that carbide tools are much more precise and exhibit reduced levels of chatter. The rough boring system will be complemented by the new EWA 68 intelligent fully automatic fine boring tool that received its world premiere at the EMO exhibition last September.

The new EWA 68 is an intelligent fully automatic fine boring tool that performs closed-loop boring operations without human intervention. With the EWA 68, there is no need to stop the machine tool to take measurements and manually adjust the boring tool. This significantly reduces cycle times, increases productivity and reduces failure rates due to human error, reduces costs and improves accuracy.

Precision, concentricity and surface finishes are only as good as the toolholders and this is why Big Kaiser has expanded its range with the arrival of the new PG (perfect grip) Straight Collet system.

Big Kaiser PG reduction collets from ITC
Big Kaiser PG reduction collets from ITC

The PG Straight Collet system includes a new anti-pullout system that locks the collet and cutter to the toolholder body, a design which eliminates cutter slippage and also the potential for cutter pull out during demanding metal removal applications. The new system is particularly suited to high dynamic milling and high-speed milling in difficult materials.

Big Kaiser has launched three sizes of collet with the new anti-pullout system – all of which received world premieres at EMO. The three size variations include a 10, 12 and 16mm PG Straight Collet system and, unlike other systems, the PG does not require specially modified and inherently expensive end mills. Instead, it uses existing standard carbide or HSS end mill designations. Standard notches found on typical Weldon-type end mills will readily accept the locking key insert on the new PG system.

At MACH, the PG system will be shown alongside the new Ultra Precision Hydraulic Chuck. The new hydraulic chuck is suitable for all machine shops that require the lowest possible runout for high-precision milling. With runout guaranteed to be less than 1µm at 4xD, this ultra-low runout retains this precise level even after intensive use.

The Big Kaiser hydraulic chuck series
The Big Kaiser hydraulic chuck series

ITC will also present a new line of hydraulic chucks for turning machines that provide outstanding repeatability and damping characteristics. The advantage of the new Big Kaiser chucks is that they enable simple and straightforward assembly using just an Allen key, while the holder remains mounted on the machine. The chucks have been designed to be compatible with major sliding head automatic turning centre brands such as Citizen, Star, Tsugami and Tornos.

Also newly introduced to Big Kaiser’s HDC (hydraulic chucks) series and available at MACH will be the Hydraulic Chuck Jet chuck series. Easy, fast and safe to use with no heat shrink clamping machines required, the life of the toolholder is extended indefinitely, saving money and reducing the environmental impact of holder replacement when compared to shrink-fit holders.

Hall 20, Stand 432

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