All Mega Chuck tool holders are precision ground finished to ensure perfect concentricity for high-speed machining tasks

As a manufacturer of high-performance electric and hydraulic sewer pipe rehabilitation robot systems, Pipetronics GmbH & Co uses two in-house CNC machining centres fitted with a wide range of BIG Kaiser tools and tool holders that can be sourced in the UK from Tamworth-based Industrial Tooling Corporation (ITC).

With a facility in Stutensee, the German company, which was founded in 2016, and employs around 100 people, uses the BIG Kaiser tools for the production of its robots’ turning and milling components.

Rolf Dettinger, head of CNC manufacturing at Pipetronics, said: “Currently, our robotic systems represent the most innovative, and ‘state of the art’ technology in the field of sewer robotics, delivering maximum performance, return-on-investment and rugged durability for uncompromising daily use. A range of customised truck and trailer vehicle systems for trenchless sewer rehabilitation coupled with specialist pipe repair resins complete our offer.”

Pipetronics’ hydraulic and electric milling, filling and grouting sewer rehabilitation robots fitted with an extensive set of milling, grinding and brushing attachments, making them ideal for a wide variety of sewer rehabilitation tasks.

He added: “The main function of these robots is sewer rehabilitation preparation works on pipe liners and the opening of inlets after the liner has been set in place. Our sewer milling robots take care of all the work, including the milling-off of edges, removal of stubborn deposits, repairs of sewer breakage points, damaged sleeves or even the milling of completely clogged sewers, all performed easily, safely and economically.”

Mr Dettinger continued: “Since we have relatively small batch runs, in 2019 we installed two CNC machines — a Grob G350 five-axis machining centre and a Mazak i400 ST turn/mill centre, to achieve faster, more flexible and economic production. Now, three years later, there is no question that this was the right decision as we are now able to manufacture top quality milled and turned parts ag a cost-effective price.”

In-house CNC production
He added: “Both of these machines were equipped with robotic handling functionality, which increased productivity and output, while simultaneously reducing our reliance on human labour — both machines run an average of 16 hours per day. We mill large parts on the Grob because it has a very long Z-axis, while the Mazak is used to produce complex turned and milled parts.”

To mill very close to the clamping device along the spindle, a slim, stable and precise tool holder is required - and this is where the tool holder specialist BIG Kaiser comes into the picture.

Mr Dettinger said: “From my previous job, I have significant experience with BIG Kaiser spindle tools and BIG Daishowa tool holders. After being repeatedly disappointed by the quality of the default chucks used on the Grob, I finally contacted BIG Daishowa, and was provided us with the Mega Double Power Chuck for testing.”

Christian David, BIG Daishowa key account manager, said: “Thanks to its exceptionally high holding force, the Mega Double Power Chuck is perfectly suited for high-chip-volume rough machining operations. It is also requires very low maintenance as it is perfectly sealed against coolant ingression and contamination. Thanks to the enlarged contact diameter on its clamping nut and tool flange, the Mega Double Power Chuck achieves a holding force of up to 3,200N/m, while its high stability ensures vibration-free high-performance machining operation.”

Seeing the impressive results during the test phase, the CNC production manager at Pipetronics was so impressed that he ordered several Micro collet chucks from the Mega Chuck series for the Mazak machine in addition to the tested Mega Double Power Chuck.

Mr Dettinger explained: “The Mazak has a CAPTO C6 machine interface, which is ideal for turn/mill operations. For our application, the BIG Micro collet chucks offer optimal performance characteristics for machining hard-to-reach workpiece areas, where conventional collet systems fail to deliver. Thanks to its groove-free collet nut, vibration at high speeds are avoided.

“The key is that the BIG Kaiser Micro collet system is slim enough to implement in all our machining operations. We mill at 12,000rev/min on the Mazak and all BIG Kaiser collet chucks have a guaranteed runout of less than 0.001mm at the collet mouth. Initially available in only one size, we now run our Micro chucks in a wide variety of lengths and diameters.

“Our cooperation with BIG Kaiser has delivered excellent results. We currently produce over 890 different parts on our machines and the tool holders from BIG Kaiser make our processes faster, more flexible and reliable, while being more cost-effective.”

He concluded: “We cannot stress enough how pleased we are with our BIG Kaiser spindle tools. The power chucks and collet chucks have made a significant contribution to the production of intelligent robots for the harshest of environments.”