EWA achieves fast, accurate boring because the process does not need to be stopped to make measurements or manual adjustments. As well as saving time, this instils confidence in the operator, and minimises costly scrap that can result from manual adjustment errors.

Importantly, the EWA’s motor is sealed against dirt and water to IP69 rating. The clamping system provides additional stability and repeatability to deliver consistently high levels of reliability and precision at cutting speeds above 200 m/min.

EWA can be used with Big Kaiser’s standard range of accessories, making it an easy addition to existing systems. To maximise flexibility, the tool offers an adjustment range of 22 mm, which ITC says is substantially larger than similar solutions available in the market. Furthermore, the system has an integrated accelerometer that measures vibration during the cutting process and, in the event of excessive vibration, alerts the machine to automatically adjust its cutting parameters.

Jose Fenollosa, head of R&D at Big Kaiser, says: “The EWA is far ahead of the rest in its level of automation and sophistication, and this gives our customers real benefits in terms of time and money saved. It also makes it ideal for Industry 4.0 applications. We are talking to potential customers now, including some leading machine-tool manufacturers.”

Initially, EWA is available in two versions. The EWA Peripheric covers diameters from 68 to 90 mm, while the EWA Centric incorporates a central boring bar with internal coolant for smaller diameters. Further models for different adjustment ranges are currently in the design phase.

The demonstration at EMO 2019 was undertaken on a FANUC CNC machining centre, whereby the entire boring cycle was performed automatically. This operation included the initial bore machining, subsequent measuring and the adjustment process to complete the final precision bore.

EWA features wireless connectivity to Big Kaiser’s smartphone and tablet app for easy tool monitoring and configuration. The tool can also automatically communicate with a pre-setter, so diameter measurements can be transferred without operator intervention.