High-precision tooling systems Smart dampers bring vibration-free boring to smaller diameters
Big Kaiser launches two new EWN Smart Damper precision boring heads that utilize a patented damping system to eliminate vibration from deep-hole finish boring.
According to Big Kaiser, the new EWN Smart Damper increases productivity by up to a factor of ten, achieving noticeably better surface finishes and improved metal removal rates. For the first time, two new EWN Smart Damper boring heads enable the coverage of diameters below 32 mm, down to 20 mm. The CK1 head has a length of 100 mm and the CK2 head has a length of 125 mm.
The design of the Smart Damper heads shortens the distance from the damping mechanism to the cutting edge, i.e. the source of vibration. This significantly improves vibration damping performance at the tool assembly, minimizing chatter and vibration, thus making it ideal for critical applications requiring very long tools, for example in the automotive, energy and aerospace industries.
The company's modular CK/CKB system is compatible with most major spindle interfaces and enables versatility in tooling combination lengths up to a maximum of 10 times diameter. All tools have a coolant-through design and offer three different insert holder options per head size.
Following the initial modular boring system and milling type, it has gradually added mono-block type finish boring, mono-block type rough boring, CK shank type and finally turning type variants. The two new smaller sizes of the Smart Damper will be added in mono-block type finish boring for CK1 and CK2, which cover diameters from 20 mm to 36 mm with CK1, and 25 mm to 47 mm with CK2. While these diameters would normally be machined by an extra-long carbide bar under very conservative conditions, the new Smart Dampers allow for more aggressive settings, where the carbide extension is combined with the new mono-block types. For example, a 220 mm carbide bar combined with a CK2-EWN-25DP-125 Smart Damper can achieve an L/D11 bore (material GGG50, projection 380 mm, Vc 300 m/min, f 0.06mm/rev, DOC0.2 mm/φ) on a No. 50 horizontal machine. Center-through coolant and back boring are also available for the new models — in all finish boring types. The new Smart Damper models will be available from April 2021.