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
One of the biggest advantages to a program like Big Kaiser’s modular boring system is its built in versatility. You start with a list of tooling manufacturers and give them the application. OK, I need a Cat 50 tool to reach over 14″ into a part. Not a problem for many, although most will have to stack so many extensions that runout at the cutting edge will be a problem. Oh, by the way, we need to back bore this part to hold .0002″ concentricity. Everybody else tosses in their cards except Big Kaiser. We flip the insert holder on a standard 310 boring head and cut the part. Case closed.
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…