BIG-PLUS dual-contact spindles now licensed to almost 170 tool manufacturers

Manufacturers may already have the highly accurate, robust BIG-PLUS spindle interface without even knowing it and now, Industrial Tooling Corporation (ITC) can provide a simple method for quick on-site BIG KAISER verification.

As a global leader in premium high-precision tooling systems, BIG KAISER has announced that in addition to an already extensive list of licensed machine manufacturers, eight more have recently become licensed to utilise the BIG-PLUS spindle and tooling systems on their machine tools.

The BIG-PLUS solution available from Tamworth cutting tool specialist ITC is unique and provides substantial advantages over competing industry spindle designs. It is the only system that provides simultaneous taper and flange contact in a 7/24 cone interface. This dual-contact connection between the machine and the tool makes it exceptionally robust, reliable and accurate.

There are now nearly 170 manufacturers licensed to implement the BIG-PLUS spindle on their machinery. Despite the fact that BIG-PLUS was developed over 25 years ago in Japan, the adoption of BIG-PLUS spindles is steadily seeing, solid growth across the industry. The full list of big and small names can be found at https://www.bigkaiser.com/en/big-plusr-spindle-system-machine-tool-builders.

Christian Spicher, Head of Sales and Marketing at BIG KAISER, said, "Many manufacturers will already have BIG-PLUS compatible machines, and many of their spindles may actually be BIG-PLUS compliant, but they may not be aware of this important fact. This means that machine tool users are missing out on the substantial benefits provided by this rigid dual-contact interface.”

For customers who are unsure whether they have a BIG-PLUS spindle, the easiest way to check compliance is to place a standard tool into the spindle and see how large the gap between the tool holder flange face and spindle face is. On machines without the BIG-PLUS system, the standard gap for DV50 should be clearly visible at approximately 3.2mm. With a BIG-PLUS DV50 spindle, the gap is approximately half the size. Naturally, gap sizes vary accordingly for DV40 and DV30 configurations. Nevertheless, with BIG-PLUS the gap is always visibly smaller compared to alternative spindle interfaces. Alternately, manufacturers can ask their local ITC representative to confirm compatibility.

While competitors offer ‘dual-contact tool holders’ that claim to provide a similar flange and taper contact solution to BIG-PLUS, these holders are not typically made to sufficiently tight tolerances and may not provide a sufficiently rigid contact interface. Using unlicensed tool holders unnecessarily risks a less robust connection as well as expensive spindle damage, potentially voiding the machine’s warranty.

To help its customers, BIG KAISER has developed a simple test that can easily determine whether a tool holder is in fact a genuine BIG-PLUS spindle or an unlicensed dual-contact tool holder.

If a BIG-PLUS spindle is used with standard V-flange tools, over time this will result in wear on the spindle and alter its geometry. Since a rigid simultaneous taper and face contact is required, geometry is a critical factor, and even minor deviations will impair the BIG-PLUS spindle ability to deliver its full potential.

To address this issue, ITC can now offer customers special spindle and tool taper cleaners, as well as arm alignment tools. However, to restore a BIG-PLUS spindle to its proper specifications, the most effective option is a certified regrind. The BIG-PLUS system was invented by BIG KAISER’s parent company, BIG Daishowa in 1993. Its time-proven superior vibration damping and rigidity noticeably improve machining accuracy and repeatability. This facilitates heavy duty and high-speed cutting whilst also providing a longer tool life. For example, when compared with a conventional BT holder in shoulder milling tests, the BIG-PLUS system reduced the deflection of a machine part by 30%.

The BIG-PLUS solution ensures that as the tool enters the machine spindle, the taper makes the initial contact. Due to the pull-in force, the tool taper expands the spindle in the elastic range of the steel. The tool is then pulled further into the spindle until the tool flange reaches the surface of the spindle nose. These tool holders are firmly held to a fixed relationship between the gauge line and the face with a tolerance of only a few microns. With such a tight tolerance, BIG KAISER can be sure that any BIG-PLUS tool put into any BIG-PLUS spindle will have the proper taper and face contact. Having the same dimensions as conventional BT or SK holders; BIG-PLUS is fully interchangeable with existing accessories. To benefit from the huge benefits of the BIG-PLUS system, please contact ITC to confirm compatibility. If your machine tool is BIG-PLUS compatible, ITC will undoubtedly have the tool holding and clamping solutions to drastically improve the productivity, precision, surface finish and tool life benefits of your business.