Spindle interface technology Tool holders put to test
UK — More than 150 machine tool manufacturers worldwide are already adopting the Big Kaiser BBT spindle interface technology that is available from Industrial Tooling Corporation (ITC) under license. The company recently put its equipment to the test against leading industry rivals to underpin the underpin the superior performance claimed by the manufacturer.
Big Kaiser conducted several cutting force performance tests with Kistler, a world leader in measurement, analysis and sensor technology. The tests compared Big Kaiser tool holders with competitor products; measuring cutting forces over a period of time to provide customers robust recorded real-life data regarding the stability of machining operations.
To achieve objective tool holder comparative test results, Kistler used its cutting force measuring chain that comprises a Kistler 9119AA multi-component dynamometer, Labamp laboratory charge amplifier and Dynoware analysis software. The testing process measured and compared attributes such as imbalance and concentricity of each of the tool holders. Furthermore, the test monitored machining characteristics such as chip quality, noise development and machined surface quality.
Big Kaiser applied its Mega New Baby Chuck to the test and compared its side milling cutting results with that of three competitor tool holders. The Mega New Baby Chuck ran with a ø12 mm solid carbide end mill that machined tempered steel (C45E) at a feed of 10 m/min with an axial depth (Ap) of 12 mm. For a meaningful comparison, the measured radial depth of cut (Ae value) started at a fine finishing depth of 0.5 mm, gradually increasing in increments of 0.5 mm at each step of the test.
According to the company, the test results clearly demonstrated that the chuck allowed for the highest Ae values, while still maintaining vibration values at an acceptable level. Competitors' tool holders were shown to achieve only 50 to 70 percent of the Big Kaiser tool holder performance, indicating that the tested chuck demonstrates higher removal rates and greater throughput with superior cost efficiency and a longer tool lifetime.
As a measurement, the cutting force is representative of many tools and material combinations directly related to a tool’s lifetime. By evaluating the measured force curves and trends, it is possible to determine the wear mechanisms that are responsible for tool load and to implement appropriate improvements.
Furthermore, tool stability is directly related to cutting force. The impact on stability can be deduced from the dynamics of the forces before any visible effects become evident. This enables additional interesting insights into the process. For example, the cutting force measurement shows whether the cutting point, i.e. the point at which the tool dips into the material, causes high force deflection.
Big Kaiser has also performed Kistler cutting force tests on other products in its tool holder range, including the hydraulic chucks (Standard and Jet-Through), Hi-Power Milling Chuck and Mega-E Collet Chuck. In every application and test, the results were comparable to those achieved by the Mega New Baby Chuck, the manufacturer states.