Tag Archives: Big Kaiser Precision Tooling

Tooling Dictionary…

Rel-e-gate (verb) ; consign or dismiss to an inferior rank or position

Example: The customer relegated the inferior boring heads to the cart while the Kaiser heads stayed in the machine making round bores that did not taper from top to bottom.

We ran 112.118 Kaiser finish boring heads in 303 Stainless steel on a Cat 40 Haas Mill, holding .0005″ tolerance and .0001″ roundness. Excellent results with the new Alcona coated inserts. Note in the photo below how the competition’s heads have small – difficult to read adjusting dials. Additionally, note how the boring bars mount on the head, fixed at a great distance from the main body.

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New Big Kaiser Boring System Rewrites The Rules

An Elk Grove Village based aluminum die-cast house and machining operation isn’t afraid to go all in with their tooling. In a highly competitive market seconds count in any operation. One place most wouldn’t look to be able to save time is with an 11.75″ diameter bore on an older BT40 mill, but with a new tool from Big Kaiser the rules have changed. Why can’t we run faster on larger diameters and on smaller taper machines ?  Tool weight is the key: too heavy to get the SFM’s up, too heavy to tool change. With the new series 318 boring system from Big Kaiser, both of these questions were answered with an off the shelf tool. Series 318 uses anodized aluminum components for the strength of steel with a substantial decrease in tool weight. Additionally, the new system allows for integral slide components to further reduce weight and the additional cost of multiple components. When the customer asked what we might have available for the application, it could not have been better timing for this product. Here are the net results in the customer’s email to me after the tool test. The only issue they had was clearance in the magazine with a large tool on a BT40 machine:

“That tool is awesome. We had to modify pot in, pot out sheet metal and  that’s it.

Ran a part 2400rpm @ 19.2ipm with the regular inserts (carbide) you set up, looks beautiful! “

That’s 2400 RPM on an 11.5″ diameter..do the math on the SFM’s yourself. I think many, many,  large production bores are now up for review.

11.755" diameter on a BT 40 flange. Tool weight approx. 15 pounds

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Speroni Delivers Under the Covers…Competition, Not So Much.

This may be a bit of a long post and sorry for the bad tag line but hang in there…

I installed a new Speroni Magis presetter at a customer in the Chicago area last month. While it was good fortune for me and the customer is very pleased with their new machine, it was a bit of a tough pill for them to swallow. They purchased our new presetter due to the almost constant breakdowns to their only three and a half year old existing unit. Why did they have to replace such a relatively new piece of equipment? Well, I had the opportunity to take a look under the covers of my competitors unit and to say I was a bit surpised is an understatement. I’ve attached a slide show of some pics of the competition’s unit and I would like to point out a couple of  design features that over time, proved to be their undoing.

First, take a look at the large voids in both the base and column castings. My customer felt that with larger, heavier tools in their 50 taper spindle, the machine would not repeat. I can understand this due to a lack of support from the castings. Trying to hold tenths with lack of stability is hard to achieve. Secondly and where the customer had multiple problems, is the completely unprotected gold colored glass scale strips along the x and z axis. Even with the covers and bellows installed, contaminants were making their way into the machine and causing the scales to misread. The readout would jump by as much as .010″, the guys in the tool crib were actually using a 20 year old height gage at the end to set lengths out of fear of crashing tools due to bad measurements. My customer machines a lot of stainless and still had contamination problems – good luck in a cast iron shop!

Needless to say, the quality of construction that goes into both table top Speroni Magis and floor model Esperia presetters could never allow for these pretty glaring deficiencies. Solid castings, massive guideways and sealed Heidenhein scales are the foundation for constructing a machine that is designed to last decades, not months on the shop floor. If you’re coming to IMTS 2010 and in the market for a presetter, stop by Big Kaiser at booth W-1600 for a look at the Speroni machines. We’ll give you a look under the covers.

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In Case You Missed It….

Congratulations to all at Big Kaiser who put it a lot of effort to make the Grand Opening event a success. With representatives from Big Daishowa Seiki Japan, Heinz Kaiser in Switzerland, Speroni SpA Italy and Innotool Austria, guests were treated to multiple new product introductions. Highlights included  the  1 Micron adjusting EWB-UP boring heads, the ultra high precision Mega ER Grip collet system, and the latest Magis line of tool presetters. A few pics below of the showroom with machining centers for demos and the new training room.

If you missed it, give me a call and we can make a visit over for a tour, lunch is on me…

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