Toolholders – IndMacDig | Industrial Machinery Digest

CAT Tool Holders Explained: The What, Why, When and How of America’s Original Tool Holding System

Industrial Machinery Digest — Mon, 18 Aug 2025 20:06:39 +0000

CAT tool holders remain a reliable and versatile choice for many machining operations, with compatibility across a wide range of machines and applications.
Choosing the right size, style and premium features can greatly improve rigidity, accuracy and overall performance.
BIG-PLUS technology enhances CAT tool holders by providing simultaneous spindle face and taper contact, increasing stability and precision in high-speed and high-accuracy applications.

When it comes to spindle and tool holding systems, there’s one original that every machinist has likely encountered: CAT. Short for Caterpillar (yes, that Caterpillar!), it was invented about 50 years ago by engineers at the company, and quickly became the gold standard in the U.S. Steep-taper-style tool holders like CAT (and BT in Europe and Japan) dominated the market for decades, until the advent of other specialized systems like HSK and CAPTO. These systems rose in popularity by ushering in a new era in high-speed cutting and micromachining—allowing for speeds in excess of 50,000 rpm. But advances in CAT-type tool holders (including BIG-PLUS technology) mean that this tried-and-true system is still in heavy rotation in many machine shops.

What Is a CAT Tool Holder?

CAT tool holders are a type of steep-taper tool holder with a 7:24 taper ratio. As mentioned, they were invented in the 1970s by Caterpillar engineers, but the original design dates back to a patent filed in 1927 by Kearney & Trecker Corp., Brown & Sharpe Manufacturing Co. and Cincinnati Milling Machine Co. Think of CAT tool holders as the strong, heavy workhorses of the machining world: they are steady at reasonable speeds, reliable, powerful and efficient. Let’s take a look at their anatomy:

V-flange

The V-flange is an element of CAT tool holders that was intrinsic to its invention: the element that enables the use of automatic tool changers (ATC). It’s named for the V-shaped groove, which ensures that the ATC can lock onto the tool holder and facilitate spindle attachment.

Taper

As mentioned, another hallmark of the CAT system is its 7:24 taper. The taper is the interface between the tool holder and the spindle–a vital element that ensures rigid contact and repeatable centering between the two. In the case of steep-taper tool holders like CAT, it’s easily defined by its conical shape.

Retention Knob (Pull Stud)

Retention knobs, also known as pull studs, are the key element that keeps the tool holder attached to the spindle. They’re a small—but vital—component, but all too often overlooked. Using any old pull stud off the shop floor shelf can result in poor retention, which leads to chatter, poor quality and even catastrophic safety issues. Avoid issues by using premium quality retention knobs (same for all other tool holder components).

Key Features and Benefits of CAT Tool Holders

Steep-taper tool holders—CAT included—are perhaps the most common for a reason. They’re big and heavy for rigidity; they offer excellent application flexibility; they enable quick, efficient tool changes; and with technology like BIG-PLUS, they can offer the same dual-contact function as systems like HSK and CAPTO.

As mentioned, the V-flange was a notable design advantage when it was invented and continues to be a staple—enabling quick tool changes. The taper design of CAT tool holders is meant to provide high rigidity and accurate centering–ensuring even loads during cutting to help extend tool and spindle life.

Generally, however, any good tool holder should cover the previously mentioned benefits. So what makes CAT different? The all-purpose nature of this tool holder type is a big part of its appeal. Chances are, many of the CNC machines on your shop floor are compatible with steep-taper tool holding, and CAT tool holders are widely applicable to a variety of machining operations and tool types and sizes.

Factors to Consider When Selecting CAT Tool Holders

If you’ve made the decision to use (or are already using) CAT tool holders, you still have some choices to make in terms of size, brand, application, etc.

Sizing for CAT tool holders is fairly simple—most machining centers call for CAT40 or CAT50 sizes. Smaller machines and applications may use CAT30. CAT60 is another option but is much less common—only used in the very biggest machine tools.

More importantly is your choice of tool holder type—from collet chucks to hydraulic chucks. The choices are almost endless, so it’s crucial to talk to a tooling expert about your specific applications and needs, but here are a few specific nuggets:

CAT systems can accommodate micromachining too! Micro collet chucks feature a slim design vibration-minimizing features.
Hydraulic chucks are a good choice for high-accuracy applications like automotive, aerospace, medical and die and mold.
Choosing between shrink-fit and hydraulic holders for long-reach applications? Hydraulic tool holders offer great runout and repeatability, but only within their rated RPM. Shrink-fit holders are a bit more accommodating of excessive speeds but may have a slightly higher baseline runout.
Regardless of the type of tool holder you choose within the CAT system, look for premium, value-added features that increase rigidity. This can be especially important because standard CAT systems are not dual-contact, which can increase the risk of vibration and chatter.

BIG-PLUS: The Best of Both Worlds

Speaking of value-added features, there’s one major option you can use to level up the performance of your CAT tool holding.

A shortfall of traditional CAT tool holding is that, unlike other tool holding systems like HSK and CAPTO, it is not inherently dual-contact—meaning standard CAT tool holders do not deliver simultaneous contact between the spindle face and the V-flange. This can be an issue in high-speed and high-precision cutting applications because a single-contact tool holding setup isn’t as rigid, potentially causing chatter and deflection.

Fortunately, longtime CAT users seeking the benefits of dual-contact tool holding don’t have to overhaul their machining operation. Chances are, BIG-PLUS dual-contact spindles are already in use on the shop floor. And in combination with licensed, CAT-style BIG-PLUS tooling, machinists get true dual contact between the spindle and tool holder. And the difference is significant—watch this video to see the performance of a standard CAT40 holder vs. a BIG-PLUS CAT40 holder.

Whether you’re a CAT loyalist or a user of multiple spindle-tool holder interfaces, investing in premium tool holding technology can make all the difference in your operation. Discover all the options available and talk to an expert today about your needs and challenges.

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Industrial Machinery Digest

From Downtime to Peak Performance: The Case for High-Precision Tool Holders

Industrial Machinery Digest — Tue, 15 Jul 2025 22:16:35 +0000

Is a good tool holder the glue that holds your job together? We think so. Not only because it can make or break efficiency, profits and part quality, but because it’s all too often overlooked. While inserts and tools do the cutting and the spindle does the spinning, both are dependent on the stability and quality of the tool holder.

In fact, one of the biggest cost savings to be had in your shop—achieving better tool life—isn’t solely dependent on speeds, feeds, programming or advanced insert grades and coatings; rather, the tool holder is the most constant variable across all applications. But don’t take our word for it. Read on to see real-life stories of how the right tool holder solved serious cutting challenges—reducing runout, streamlining operations, enabling efficiency and boosting part quality.

Project Saved With BIG-PLUS Tech

Mecanizados Laguna made parts for every industry from mining and automotive to food processing. But it faced a puzzling challenge while working on a large geared motor housing component. The part required multiple deep holes with extremely precise parallelism and tight tolerances in the cylinder liners; space constraints and material stress from oxyfuel cutting and welding made things even more challenging.

“We were struggling to get to the measurements we needed. Then, BIG DAISHOWA engineers’ advice came to mind, and we turned to see our BIG-PLUS spindles,” explained Joel García, CNC machining manager at the shop.

Fully leveraging the power of their machine’s BIG-PLUS spindles with true, BIG-PLUS dual-contact tool holders was a game-changer. The solution delivered more rigidity, thanks to the simultaneous contact between the tool shank and spindle face. This quickly resolved the parallelism, circularity and concentricity issues. As a welcome surprise, productivity tripled. Now, operators could machine three holes per insert edge (as compared to one previously) and manufacturing time was cut in half—from one month to just two weeks.

It wasn’t just about the technical successes. Instilling confidence with key clients—and ensuring repeat business—was perhaps the biggest win.

Tool holder for the WIN: BIG-PLUS Dual-Contact Tool Holders

Better Molds With Better Milling Chucks

The mold manufacturing market in Mexico is competitive and the requirements are steep: tough-to-machine hardened steels, tight tolerances and mirror-like surface finishes. In 2019, Jorge Rucoba’s Monterrey-based machine shop Taller de Maquinados was in desperate need of a productivity edge. Despite investing in new CNC equipment, the shop still had issues. Machining processes were slowing, sometimes by as much as 50%; tool wear, poor surface finishes and low machining accuracy were becoming common; and setup and cycle times were simply unacceptable.

After determining that the issues weren’t due to the new machining center, BIG DAISHOWA engineers traced the issue back to poor tool holding performance. By switching to Hi-Power Milling Chucks, the shop immediately saw dramatic improvements: machining speeds more than doubled (from 400 to 800 SFM, 80 to 200 IPM and 3,300 to 4,400 RPM), improving total cycle times by 50%. What’s more, tool life was extended by 80%, significantly reducing production costs. The new milling chucks are so reliable, Rucoba says he’s confident enough to let machines run unattended.

The improvements have helped the shop attract new clients and establish itself as a competitive player in Mexico’s growing mold market.

Tool holder for the WIN: Hi-Power Milling Chucks

Taking Flight With Advanced Tool Holding

When you’re supplying components for Blue Origin space flights, perfection is mission-critical. Baker Manufacturing was eager to deliver, but the challenges of complex, closed-angle features and exotic materials—including Inconels, titaniums, and even experimental alloys with unknown chemical compositions—aren’t for the faint of heart. Under the gun with tight deadlines, the shop needed to have an extensive, flexible tooling collection at the ready.

Some of the best investments in its inventory? Tony Baker says the BIG DAISHOWA universal angle heads, which help operators access difficult angles and complex pockets; and the BCV50-Mega Series milling chucks with BIG-PLUS dual contact technology.

The vibration-damping capabilities of the milling chucks make dollars and cents for the shop—to the tune of thousands. By delivering better tool life, $400-$600 nine-flute mills can machine 20 parts instead of just one. Not to mention the reduced risk of ruining a $10,000 aerospace workpiece.

With these two tool holders in its arsenal, the sky (or rather, space) is the limit for Baker Manufacturing.

Tool holders for the WIN: BCV50-Mega Series Milling Chucks and Universal Type Angle Heads

Prototyping for Success with Micro Tool Holding

When it comes to prototyping, Trek Bicycle’s Development Lab doesn’t like to spin its wheels. In fact, when an engineer proposes a new part idea, the lab has only 10-14 days to turn around the prototype—a fresh programming challenge every single time.

The challenge of creating new, one-off bicycle components with complex 3D surfaces and deep, tight pockets requires toolholding solutions that provide excellent accessibility without sacrificing rigidity or time-consuming setup procedures.

After getting a new 5-axis machine, Trek used CAM software to program a tool path that would enable the machine to automatically tilt to avoid tooling/workpiece collisions. But with standard ER 32 or 16 tool holders in a deep and tight pocket, the machine had to tilt significantly to clear the body of the holder, which meant excessive axis movements and the potential for machine collisions.

Extensions weren’t an option due to the runout they would create, and expensive shrink-fit holders weren’t worth it.

BIG DAISHOWA’s MEGA Micro Chucks came through in the clutch, with ultra-slim nut diameters as narrow as 0.394″ and shallow taper angles that deliver rigidity and superior pocket access. The profiles and shape of the chucks was the same as the shrink-fit holders they were considering, but with the added flexibility of collets.

Cory Marty, Trek’s senior engineering technician, estimated that this solution immediately eliminated about 50% of their reach issues, and reduced machine tilting to just 10 degrees, enabling higher speeds and feeds and better surface finishes. All without unnecessary expenditures on tooling extensions or less-than-ideal shrink-fit setups.

Tool holders for the WIN: MEGA Micro Chucks

Racing Against Time With Precision Tool Holding

In racing, every second matters—and for Team Penske, that urgency extends to the machine shop. Any improvement made in a part could add up to crucial time shaved off each lap around the track. What’s more, shop teams are operating on the fly, modifying parts constantly between races—sometimes in as 6-8 hours. It all adds up to about 50,000 parts annually across 2,000 part numbers, all of which require championship-level precision. And because cars must be lightweight, components are usually made from tricky materials like aluminum, titanium and steel components, with the need for extended reaches and tolerances as tight as ±0.0005″.

So when it comes to tool holding, success requires a strategic combination. For Penske, it starts with Mega ER collet holders, which eliminated deflection and runout issues in long-reach reaming operations, achieving less than 0.0002″ runout on 10″+ extensions. Next, Hi-Power milling chucks solved vibration problems in high-speed aluminum applications, allowing spindle speeds to increase from 1,834 to 2,620 SFM while extending tool life by 30%. Finally, digital boring heads boosted precision even more by eliminating test cuts and enabling real-time adjustments down to 50 millionths, resulting in 80% faster bore finishing processes.

The real benefits come when rubber meets the road: Team Penske has dozens of wins under their belt, proving that precision tooling can be the difference between victory and defeat.

Tool holders for the WIN: Mega ER Collet Holders, Hi-Power Milling Chucks, Digital Boring Heads

Now you’ve heard the case for premium tool holding technology. But how do you know what makes it premium and which tool holders will achieve the results you need? Read more about how to evaluate tool holder quality here, or talk to a BIG DAISHOWA expert today about your needs and challenges.

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Industrial Machinery Digest

BIG DAISHOWA’s Wide World of Spindle Systems and Tool Holders

Industrial Machinery Digest — Tue, 15 Apr 2025 16:11:23 +0000

Because the BIG-PLUS spindle system gets so much of our customers’ attention and interest, people often forget that BIG DAISHOWA offers an extensive line-up of other popular dual contact solutions, most notably HSK & BIG CAPTO. Across the board, dual contact tooling offers superior rigidity, accuracy and repeatability when compared to conventional systems. Each of the systems above has its fans and detractors, but overall, each does a great job for what it was intended to do. We’re certainly partial to the overall rigidity, precision and repeatability of BIG-PLUS, but understand that there’s a place for all of these interfaces – which is why we offer them.

BIG DAISHOWA offers virtually all of our tool holding systems in all three major dual contact designs, such as our well-known collet chucks based off of the New Baby Collet, and our heavy duty milling chucks. But we didn’t stop there. In dual contact, we also offer ER collet chucks, hydraulic chucks, shrink fit holders, shell mill holders, end mill holders, modular adapters, turning tools for MTC’s, integral milling cutters, holders for rigid tapping and much more!

And since we are on the topic, when it comes to shrink fit, it’s indeed true that as a whole, they offer high clamping forces, low runout, and a small nose diameter to reduce clearance issues. BIG DAISHOWA manufactures shrink fit holders to the highest standards with the highest quality materials. This enables us to slap our promise of “Higher Performance. Guaranteed.” on each that we sell.

That being said, while shrink fit tools have carved out a definite place in metal cutting, our stance is that you pick the right holder for the job, no matter what it may be. For instance, when heavy duty milling with large diameter cutters, there are other options that can offer even better gripping force and at the same time, better runout than shrink fit. Our mechanical milling chucks such as the Mega Double Power and Hi-Power Milling Chucks offer higher gripping strengths for large cutters with minimal runout. For finish milling under ½”, BIG DAISHOWA’s Mega E Collet Chucks, for instance reduce the runout to no higher than .0001″ @ 4xd guaranteed, while a thick walled design and tapered body adds to the rigidity while not being too bulky for tighter areas. All of these options, used in the right application for what they were intended, will give you better results than shrink fit will. And they are more flexible thanks to long and slender interchangeable collets, and much easier to handle than shrink fit.

The bottom line is, to maximize productivity, it’s important to use the right tool for the job, and not to try and chose one end-all solution for your shop. That’s why BIG DAISHOWA offers not only the best, most precise, most accurate products available (even though we think these are pretty cool), but offers a complete complement of different tool holder styles for any application, and for any modern machine tool spindle.

View our collection of catalogs spanning our entire offering of products here.

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Industrial Machinery Digest

REGO-FIX to Feature High-Performance Toolholding System at EASTEC 2025

Industrial Machinery Digest — Mon, 24 Feb 2025 16:50:18 +0000

REGO-FIX USA will feature its industry-leading powRgrip® toolholding system in booth #5350 at EASTEC, May 13-15, 2025, in West Springfield, Mass. the company developed its powRgrip system for high performance and stable toolholding when machining parts made from all types of materials. It delivers the most effective clamping force and vibration damping combination in the market.

The powRgrip system uses a taper-to-taper, press-fit collet holding design that creates a vibration-damping gap to interrupt the strength and severity of vibration waves. Three components make up the powRgrip system: holders, collets and press-fit assembly mounting units. Toolsetting is accomplished in no more than 10 seconds without heat or hydraulics used in other tool-clamping systems. REGO-FIX’s powRgrip technology allows tools to be used immediately after the clamping cycle concludes without the limitations and tool-life compromises of other systems.

REGO-FIX offers powRgrip systems that accommodate cutters up to 40mm (1.500”) in diameter and ensures total indicated runout (T.I.R.) of under 3 microns (0.0001”) for tool lengths up to 3 x diameter.

“Reducing cycle times, improving part accuracy and maintaining process repeatability is top of mind for all manufacturers,” says Jeff Schemel REGO-FIX’s General Manager, USA. “From aerospace to medical and all industries in between the powRgrip system helps companies efficiently manufacture each part to exact tolerances and with extraordinary surface finishes.”

About REGO-FIX

With U.S. headquarters in Whitestown, Indiana, REGO-FIX, inventor of the original ER collet system, is a world leader in the manufacture of Swiss precision tooling.

For more information on REGO-FIX, its products and services, or to request a catalog, please call 1.800.REGO-FIX or visit the company’s website at www.RegoUSA.com.

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Industrial Machinery Digest

Air Turbine Technology Inc. Highlights Air Turbine Spindles® New 601 Series at 65,000/90,000 RPM

Industrial Machinery Digest — Sat, 22 Feb 2025 15:50:34 +0000

Air Turbine Technology Inc., the leading manufacturer of revolutionary high-speed turbine products, highlights its new Air Turbine Spindles® 601 Series Spindle. This innovative spindle combines constant high-speed in cut, energy efficiency and a user-friendly design. As a result of its governed high-speed performance the 601 Series is an invaluable addition in any CNC magazine to accelerate productivity and reduce costs in today’s fast-paced industrial landscape.

The compact 601 Series Spindle incorporates Air Turbine Technology Inc.’s patented governor technology, which increases CFM airflow on demand to maintain constant speeds of 40,000 to 90,000 RPM under cutting load on the toolpath through the program. The 601 Series Spindle provides up to 0.2 HP (0.15 kW) power, delivering ample power for micro-machining applications – although Air Turbine Technology Inc.’s range includes spindles with power to 1.4HP (1kW) for larger tools and hard materials.

This unique governed turbine maintains the required surface feet per minute (SFM) and chip load for micro and small tools by sustaining high RPM on the toolpath.

Cycle Times are routinely reduced 6 to 10 x compared to standard CNC spindles at 6,000 RPM to at most 20,000 RPM. Maintaining high-speed in cut also optimizes tool performance, eliminating tool breakage and ensures the production of standardized high-quality parts.

Air Turbine Technology Inc.’s direct drive 601 spindle generates no heat, delivering consistent with 2-micron accuracy with no thermal growth in the spindle. No maintenance is needed and just 2 moving parts makes this high-speed spindle reliable.

A connection to 90 psi (6.2 bar) air is all that required to make any CNC a high-speed machine. Fully automated loading is available using air supply through the machine spindle, a collar and stop block or manual connection through the side air inlet. Easy installation minimizes downtime, allowing manufacturers to quickly adapt to changing production demands.

The high-speed capabilities of the 601 Air Turbine Spindle® streamline production by the elimination of secondary operations. Moreover, micro tools are expensive. Big savings result from optimization of small tool performance and life. Governed high-speed also enhances the overall surface quality of the finished products.

The 50 mm extended barrel on the 601 Series reaches into tight workpiece operations allowing greater maneuverability and access to pockets, angles and hard-to-reach areas. These dimensions enhance access and tool performance on all machines, including those with limited Z-Axis travel as well as 360˚5-Axis programming. Another great advantage is that the 601 design eliminates the need for long cutting tool stick-out from the spindle collet in angles or pockets causing vibration, tool breakage and poor surface quality.

Precision is paramount in the 601 Series Spindle design. Notably, Air Turbine Spindles® generate no heat, ensuring consistent accuracy during extended use. Operation with no heat also eliminates the need for a duty cycle, allowing continuous 24/7 operation without requiring cool-down periods. No lubrication is required in this high-speed turbine – eliminating contamination of parts from misting. This feature is especially important to the medical and food industries. Oil-free operation also reduces maintenance and lubrication costs.

Most popular taper options are available, including HSK-A63, CAT40, BT40, BT30, DIN30, DIN40, and 20mm JS straight shank enabling flexible use with any spindle taper.

For more information about the 601 Air Turbine Spindle® Series and its capabilities, visit https://www.airturbinetools.com/products/spindles/spindle-series/601-series/.

About Air Turbine Technology Inc.

Air Turbine Technology Inc. since 1988 has invented, patented and proven a range of revolutionary high-speed spindles, live tools, motor mounts and hand tools. Air Turbine Tools, Motors and Spindles® are high-speed pneumatic tools used by manufacturers for cutting, grinding, engraving, drilling or finishing materials in industrial processes, delivering superior performance in applications that demand high-speed, precision and reliability at 25,000 to 90,000 RPM with power to 1.4HP. This new generation of products increase airflow volume to the turbine to match cutting load, ensuring consistent high-speed without sacrificing power.

Air Turbine Spindles and Motors® operate reliably without generating heat to affect precision at 2 micron and have no duty cycle limitations. Equally revolutionary for hand tools user safety and comfort are light powerful Air Turbine Tools® operating under 67 DBA with the lowest vibration of any tools, eliminating stress and reducing injury risk.

For more information visit: www.airturbinetools.com.

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Industrial Machinery Digest

THINBIT ® MINI GROOVE ‘N TURN® ACME THREADING INSERTS

Industrial Machinery Digest — Fri, 21 Feb 2025 19:06:14 +0000

THINBIT ®, manufactured by Kaiser Tool Company, is pleased to announce the expansion of their MINI GROOVE ‘N TURN® line with ACME THREADING inserts.

MINI GROOVE ‘N TURN® ACME THREADING inserts are designed to cut thread sizes of 6 threads per inch and greater. Tools have geometry to cut standard 29° acme thread profiles. Inserts can be used to cut centralizing or stub profiles by overcutting. The inserts can be used for internal acme threads on parts with bore diameters of .325” and larger.

Available in sub-micron grain carbide grades for ferrous and non-ferrous materials either uncoated or with TiN, TiCN, TiAIN or diamond film coatings. MINI GROOVE ‘N TURN® ACME THREADING inserts can be used on conventional, Swiss and CNC machines.

Toolholders are available in round shank size 1/4”, 3/8”, 1/2” and 5/8” in steel, heavy metal and carbide. MINI GROOVE ‘N TURN® ACME THREADING inserts fit existing “MGT” series THINBIT® toolholders.

THINBIT® offers an extensive selection of 60º and ACME thread forms for both internal and external threading. Custom thread profiles with deliveries from 5 working days are available.

For more information regarding the Mini Groove ‘N Turn inserts and the entire THINBIT® line, please visit our website at www.thinbit.com.

About Kaiser Tool Company

Kaiser Tool Company, Inc. is a world leader in the manufacturing of precision cutting tools for grooving, threading and boring. Our customers know and depend on us for our:
Quality Products,
Fast Delivery,
Superior Customer Service.

Kaiser Tool Company was founded in 1964 with the purpose of supplying small lathe cutting tools that were not available as standard, in-stock items. Today, our line of THINBIT^® cutting tools includes more than 100,000 in-stock tools for grooving, threading, parting, boring and turning as well as custom tools.

In 1987 we started Laser Images^® to provide our customers with laser engravings that are clean, consistent and perfect every time. Instruments, dials, wheels, scales, cutting tools and more, we can engrave virtually anything of any shape and size.

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Industrial Machinery Digest

Big Daishowa: Coolant Delivery Has Come a Long Way

Industrial Machinery Digest — Mon, 17 Feb 2025 18:34:19 +0000

From Big Daishowa: Back in the 1980s, high-performance drills like indexables and spade drills started becoming popular. Instead of a twist drill running at single-digit RPMs, newer drills could run at 1,000 RPMs with huge penetration rates. The problem was, coolant was a must, and through-spindle coolant wasn’t even a thing yet. Fast forward to the 90s and through-spindle coolant was still the exception, not the norm, on many pieces of equipment.

Meanwhile, the drills we were developing continued to get more advanced. Customers had a decision to make: continue to drill slowly or find a way to deliver coolant to the cutting edge. We decided it would be best to solve the problem for everyone, whether they needed it or not.

That’s where Big Daishowa Hi-Jet Holders came in. The design has been around since the 70s, but it became popular in the 90s—and is still well-accepted today. The Hi-Jet Holder is a coolant inducer that gives customers the option for coolant-through-like delivery, even without coolant-through spindles. It essentially attaches external piping to the tool. For some customers, using Hi-Jet Holders with each tool was a better option than purchasing a new machine.

High-performance tools have had coolant-through from day one, because they must have it. All of our boring heads have had through-spindle coolant since the late 80s as a standard feature. But, as more and more machines in the 2000s and 2010s became standard with through-spindle coolant, we had to upgrade how it was delivered. Coolant delivery had to be a standard on more and more tools.

It’s not enough to just put the coolant from the machine out to the cutting edge, or, to say, “We have a hole through the center of this tool.” For example, coolant delivery is a fairly simple task with lathe tooling; the tool is stationary, no need to worry about coolant spraying off or getting directed in a bad place. On the other hand, rotating tools are much more complex, because centrifugal force is acting against the flow and direction of the coolant onto the workpiece and cutting edge.

Here are just a few of the ways we’ve adapted our holders to the coolant demands of modern machining.

Versatile delivery options

While the first purpose of coolant is to keep the cutting edge cool, it is also key to make sure that chips are being pushed away from the part and cutting action. When chips aren’t cleared, the tool can recut the hardened chips and lead to premature tool failure. Using the right coolant through the tool to the point of cut will drastically increase tool life over time and deliver better surface finishes.

That said, a boring head and drill are often served better by different coolant delivery methods. Our holders have been designed in a way to adapt without having to buy special accessories. Perfect Seal Nuts allow for through-tool delivery or peripheral wash delivery with a drill or end mill by simply adding or removing the seal. With the seal in, you can use it for drills because it will seal all the peripheral coolant flow, directing it through the center of the tool. If you take the seal out, it will only flow around the periphery for a powerful wash.

We even took delivery options a step further with some of our newest hydraulic chucks. Without collets or accessories, you can decide which direction you want coolant flow. By adjusting some simple ceiling screws in the body of the tool holder, you can restrict the flow to the periphery or through the tool.

On-spec pull studs

Over the last 15 years, machine builders have added proprietary sealing systems for their through-spindle coolant. These serve the important purpose of protecting spindle bearings from coolant contamination. While HSK spindles have standardized sealing, not every builder has done it the same way. These proprietary systems are something that you have to match carefully with pull studs, the tool’s pairing end. For instance, most of the steep taper pull studs that we sell in the market have at least one, if not two, O-ring seals to account for.

It’s really important that whatever the manufacturer specification is for that system to seal, we make pull studs to that specification. A leaky connection between a pull stud and the machine spindle can quickly wear on bearings, especially in high-pressure systems (approx. 1,000+ PSI).

Eliminating the need for cutting-tool alteration

The best conduit of coolant from the machine to the cutting edge is the holder, not the cutting tool. For one, not many realize a good holder with jet coolant performs just as well as a through-coolant carbide endmill at half the cost per tool. Simply put, having a versatile tool holding solution on hand that can fill the need with minimal changes is a huge benefit.

That said, some cutting tool companies or end users will grind slits in the tool shank to achieve some of the same things. It’s effective, but expensive and difficult logistically, because the tools are no longer considered standard. Jet coolant holders eliminate this cost thanks to their highly directed and pressurized delivery holes.

Another way to think of it: If I have a 3/8-in. end mill, the shank is 3/8 in. and the cutting edge is 3/8 in., so peripheral coolant is going to follow down the tool precisely; if I’m drilling a 3/8-in. hole using a drill with a 1/2-in.-shank, that coolant is missing the cutting edge.

Rigorous, high-tech testing

For holders like our Jet-Through Hydraulic Chucks and Shrink Fit Holders, we test and retest coolant-delivery prototypes diligently. With the help of high-speed cameras, we can see how peripheral holes of different angles, sizes and locations make coolant and chips react in the cut, at the moment. We go through these lengths so that we can build systems that as many customers as possible can benefit from and rationalize—whether running at 1,000 RPM or 20,000, 500 PSI or 2,000.

In the end, experiment and tinker with coolant delivery, whether it’s pressure or directional. A bigger cutter doesn’t necessarily mean you need focused, high pressure, whereas a delicate drilling job will; a certain material you thought may welcome coolant, may not. As our tooling has evolved, we’ve tried to provide the high performance required and the options to dial in coolant delivery just how you need it.

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Industrial Machinery Digest

TJ Davies Manufactures Custom Machine Components and Retention Knobs with Industry Leading Lead-Times

Industrial Machinery Digest — Wed, 05 Feb 2025 19:12:26 +0000

T.J. Davies Co., Inc., an industry leading manufacturer of retention knobs, can make custom machine components for older machines where parts are hard to obtain or are no longer available. Their engineering staff can work from detailed drawings or reverse engineer from supplied parts, using a digital optical comparator to accurately measure dimensions. Parts made of American-made 8620 alloy steel which has a high tensile strength to withstand strong centrifugal force, high load force, high feed rate, and difficult to machine material. All dimensions of retention knobs can be customized, including length, diameter, thickness of collars, dimensions between collar and knob end, thread size, and more. Additionally, customers can specify a coolant hole, taper style, and whether O-rings are required. Custom made retention knobs are sized to fit the machine tool and spindle or toolholder to maximize the toolholders performance and cutting tool life and extend the life of existing machine tool assets. A fill-in-the-blanks form is provided at https://tjdavies.com/quote-request/ to simplify the process. Typical lead time for custom retention knobs is 3-4 weeks.

“Typically, we have 2 – 3 custom jobs going at any one time,” said TJ Davies President Sherry Davies. “Customers like our short lead-times, so we get a lot of custom work. They also appreciate how our quality keeps older equipment productive and profitable.”

All TJ Davies custom retention knobs are manufactured from All knobs are machined in-house with single point threading to Imperial (Class 2A UNC) or Metric (Class G6) standards. After threading is completed, each component is heat treated to 58-62 HRC then treated with hot black oxide to military specifications for protection against corrosion. Each retention knob is magnetic particle tested and then pull tested to 2.5 times the pulling force of the drawbar it is designed for.

The use of 8620 ensures that the components will work harden over time, rather than becoming brittle as is the case with the use 9310 alloy steel. Single point threading ensures that the threads are balanced (lead-in/lead-out at 180 degrees) which is very difficult to achieve when rolling threads. Full depth is also attained for each thread. Because all machining is done with a single set-up, concentricity is achieved.

Each component is heat treated to a case depth of .020 to .030. No carb is applied to coolant through hole to ensure there is no shrinkage. Core hardness of 40HRC is standard. All retention knob surfaces (not just mating surfaces) have a precision finish of 32 RMA micro or better, ISO grade 6N. Certifications are maintained for each step and each batch to ensure traceability and quality control.

Overtightening can overly stress the retention knob, leading to premature failure, and can cause toolholder swelling and expansion. TJ Davies provides recommended torque guidelines with each retention knob shipped. Machine builder recommendations should always be used when available.

Sockets for the proper installation of retention knobs are available, individually or as a complete set of 4. All sockets and retention knobs are manufactured to exact specifications that exceed industry standards and are available through distributors nationwide.

For additional information on T.J. Davies retention knobs, pull studs, and sockets, visit www.tjdavies.com .

About T.J. Davies

Founded in 1965, T.J. Davies Company, Inc. is a leading manufacturer of retention knobs located in Mantua, Ohio. The vision of T.J. Davies Company, Inc. is to produce world-class, made-in-America retention knobs and to provide exceptional customer service. Veteran Founded, Certified Women Owned Business. Their products are available through a nationwide network of distributors.

For additional information visit www.tjdavies.com, email to sales@tjdavies.com, call (440) 248-5510, or write T.J. Davies Co., Inc., 11823 Ohio Route 44, Mantua, OH, 44255.

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Industrial Machinery Digest

Platinum Tooling Named North American Distributor for Dunner

Industrial Machinery Digest — Tue, 14 Jan 2025 19:57:39 +0000

Effective immediately, Platinum Tooling Technologies, Inc., will be selling products from Dunner, a manufacturer of guide bushings for Swiss Type CNC Lathes, in North America.

Producing guide bushings since 1935, Dunner has the know-how to manufacture guide bushings in different bore profiles, guide lengths and insert material. In addition, silicone sealants can be applied to limit chip penetration. All guide bushings are available in standard (15 microns or less), ultra-precision (5 microns or less) and ultimate ultra-precision (2 microns or less).

The company manufacturers bronze, ceramic and titane (Meehanite®) guide bushings for customer machining needs. All guide bushings are ready for machine use with finished internal surfaces and geometries designed to offer the best result with nominal size material.

Manufactured from a special cast iron, titane/Meehanite® offers an excellent compromise between the coefficient of friction and wear. Suitable for stainless steel, titanium and other materials with a tendency to “load up,” it minimizes part marking and is used extensively in medical part production.

Using high-tech ceramic, Ceramic/NewSurf® offers one of the lowest friction coefficients on the market. Specifically designed for titanium, stainless steel and other difficult materials, these bushings are often used for medical implants, in particular when the tightest production tolerances are required.

Designed with steel body and bronze insert for durability, the bronze guide bushing is the most cost-effective material to prevent marking. Best suited for non-medical parts production, the guide bushing is suitable for all non-copper materials and clamping workpiece material up to h8 tolerance.

The Dunner DunnAir Adaptive Guide Bushing System is designed to replace the original guide bushing supplied by the machine builder. The easy-to-use system adds flexibility and consistency to the machining process. With this system, the need for ground stock is eliminated. DunnAir is self-adjusting and consistent and offers four different positions for flexibility and control. In addition, the bushing has a clamping range of 0.5 mm (0.020”) to accommodate material variance, as well as eliminate downtime. Lastly, DunnAir is CNC controlled, so customers can choose the position based on the application.

About Platinum Tooling

Platinum Tooling Technologies, Inc. in Prospect Heights, IL, near Chicago, serves its growing North American customer base with an extensive inventory of machine tool accessories. Its experienced staff is dedicated to providing the most innovative tooling and technology. Platinum Tooling Technologies, Inc. serves the auto, aero, medical, woodworking, composites and other industries, as well as an ever-increasing number of machine tool OEMs, through its network of manufacturers’ representatives. Platinum Tooling is the importer of Heimatec, Henninger, Tecnicrafts, Hommel + Keller QUICK tools and REV broaching tools in North America. In addition, Platinum Tooling represents Rineck Shrink Fit Tooling and Machinery in the United States and Mexico.

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Industrial Machinery Digest

Kaiser Tool Company Celebrates 60th Anniversary

Industrial Machinery Digest — Tue, 20 Aug 2024 13:39:45 +0000

In the 1950s, William (Bill) Kaiser operated a job shop and took in jobs that other manufacturers did not want to do in house. Most of the time, these jobs were difficult and he was expected to do them quickly and for very little money.

Bill found that he continuously had to make his own tools to cut small grooves for O-rings or snap rings. Hand grinding consistent grooving tools took too long and when a tool became dull, he had to start all over again.

He had an idea. If he could make grooving tools in .001” increments with standardized bodies that could be replaced in a toolholder, he would solve his problem and have a marketable product.

It took Bill almost seven years of working at night (when he wasn’t doing his job shop work) to develop and test the design of the inserts and the toolholders. He perfected the design and was awarded patent 3,296,683.

HazelKaiser

Bill and his wife, Hazel, started Kaiser Tool Company (KTC) in 1964 with the purpose of supplying small lathe cutting tools. Lathe tools were known as bits and the tools were thin. THINBIT^® was chosen as the product name. The first THINBIT^® tools were insert sizes .010” through .050” in .001” increments made from high-speed steel with a 1/4”, 5/16” and 3/8” toolholders.

From 1964 until 1980, the production and sales of THINBIT^® tooling was done at the family home on Weisser Park Avenue in Fort Wayne, Indiana. Manufacturing took place in the garage. The employees used the bathroom and kitchen of the house. The sales office was in the attic and was accessed via a set of pull down stairs. The raw material was purchased at a local hardware store.

Bill continued to innovate and expand THINBIT^® products. Hazel designed the advertising, packed and shipped the tools, took orders, typed the invoices and juggled the money (or lack thereof) to pay the bills. Their daughter Lenore, our President, grew up with THINBIT^® in every corner of the house.

Sales were very slow in the beginning as there was little money for advertising THINBIT^® products. All revenue generated by THINBIT^® was used to pay the company’s bills and the few employees. Bill still had to do job shop work and Hazel worked at an accounting firm to generate their income. After a decade, THINBIT^® sales were sufficient to allow Bill to drop his job shop work and Hazel to leave her accounting job.

Kaiser Tool Company Westec 1992

In 1980, KTC outgrew the garage and a new facility was built on Sherman Boulevard. The site was located along the St Mary’s river and terrible flooding in 1982 threatened to destroy the business. The extraordinary efforts of the employees and a few sand bags from President Ronald Regan saved the company.

Lenore took over KTC from her parents in 1982. She increased THINBIT^® product offerings, digitized the shop and office operating systems, expanded advertising and modernized the manufacturing processes.

THINBIT^® sales took off and more employees and equipment were added. Lenore’s husband, Doug, was brought on board in 1987. Doug utilized some of the first laser marking systems to engrave THINBIT^® products with indelible identification codes and began the Laser Images division.

KTC outgrew the Sherman street location in 1994 and built a new manufacturing facility on Centennial Drive. The land purchased was large enough for a new building, future expansion and nature. The design of the manufacturing area was ahead of its time with painted floors, bright lighting and climate control. Windows let in natural light and views of animals and trees.

In the 1990’s, Kaiser recognized the advantages of CNC equipment and automation which allowed continued expansion of product lines and a focus on custom tools.

Machines, work cells, inspection equipment and material storage were added and processes upgraded until the manufacturing floor was too cramped to function efficiently. In 2018, an addition was built to significantly expand the manufacturing space.

Industries served include: aerospace, medical, semiconductor, automotive, research, protective seals, jewelry, racing and those job shop innovators working out of their garages on the next big thing.

Today, THINBIT^® is an industry leader in precision cutting tools. THINBIT^® stocks over 100,000 tools and offers millions of standard tools with fast delivery. Custom tooling is available for all products. Real people answer the phones and provide excellent service.

Bill and Hazel’s premise, during the early days, was always “customer service, quality product and fast shipment”. These are the foundations of Kaiser Tool Company and what has allowed the company to grow from an unknown entity to its respected place in the industry today.

Thank you for supporting THINBIT^® for 60 years.