OSG Announces the Release of PHOENIX® PRB Barrel & Lens Inserts

We are pleased to announce the release of our NEW OSG PHOENIX® PFB Barrel & Lens Insert Series!
The NEW OSG PHOENIX® PFB Barrel & Lens is a series of indexable inserts for finishing.

 

The following list numbers are associated with the NEW OSG PHOENIX® PFB Barrel & Lens Insert
Series:

The NEW OSG PHOENIX® PFB Barrel & Lens Insert Series offers the following features & benefits:

  • Large peripheral or bottom radius for increased milling efficiency or improved surface finish
  • Increased milling efficiency- larger step-overs while keeping the same surface finish/cusp  height compared to ball nose tools
  • Improved surface finish- reduced cusp height while keeping the same step-over compared to  ball nose tools
  • 2 insert grades based on application: XP3225 for stable milling in a wide variety of materials, and XP3310 for dry milling in cast iron and hardened steel

The NEW OSG PHOENIX® PFB Barrel & Lens Insert Series is ideal in the following applications:

  • Die/Mold Industry
  • Aerospace Industry
  • Energy Industry
  • Job Shops

 

Check out the new tools HERE

OSG Announces the Release of EXOCARB® VU-TBR End Mill Series

We are pleased to announce the release of our NEW EXOCARB® VU-TBR End Mill Series!
The NEW EXOCARB® VU-TBR is a series of taper barrel end mills for finishing.

 

The following list numbers are associated with the NEW EXOCARB® VU-TBR End Mill Series:

The NEW EXOCARB® VU-TBR Series offers the following features & benefits:

  • Increased milling efficiency due to the large peripheral edge radius and multi-flute configuration
  • Increased stepover reduces machining time compared to ball nose end mills
  • Reduced cusp height improves surface finish with approximately 60% machine time reduction compared to ball nose end mills

The NEW EXOCARB® VU-TBR Series is ideal in the following applications:

  • Die/Mold Industry
  • Aerospace Industry
  • Energy Industry
  • Job Shops

 

Check out the tools HERE

OSG Announces the Release of A Brand® AT-2 Thread Mill Series

We are pleased to announce the release of our NEW A Brand® AT-2 Thread Mill Series!
The NEW A Brand® AT-2 is a series of end-cutting edge thread mills for high hardness steel applications.

 

The following list numbers are associated with the NEW A Brand® AT-2 Thread Mill Series:

The NEW A Brand® AT-2 Thread Mill Series offers the following features & benefits:

  • Helical drilling and threading can be done simultaneously
  • Newly developed DUROREY coating enables superior heat resistance and high toughness optimized for high hardness steel milling.
  • Special cutting edge shape suppresses bending of the tool
  • Left-hand cut configuration enables climb milling to prolong tool life

The NEW A Brand® AT-2 Thread Mill Series is ideal in the following applications:

  • Hardened Steel
  • Stainless Steel
  • Cast Iron

 

A Brand® AT-2 Thread Mill Inch Sizes coming soon!

 

Check out the tools HERE

OSG Announces the Release of EXOCARB® AM-EBT & AM-CRE end mill series

We are pleased to announce the release of our NEW EXOCARB® AM-EBT & AM-CRE end mill series!
The NEW EXOCARB® AM-EBT & AM-CRE is a series of ball and corner radius end mills for post-processing of additive manufacturing and milling in hardened steels.

 

The following list numbers are associated with the NEW EXOCARB® AM-EBT & AM-CRE series:

The NEW EXOCARB® AM-EBT & AM-CRE series offers the following features & benefits:

  • Negative cutting geometry to prevent chipping in hardened materials
  • Wide chip room to evacuate chips in heavy milling operations with inconsistent stock removal
  • DUROREY coating to resist chipping and cutting heat in high hardness material

The NEW EXOCARB® AM-EBT & AM-CRE series is ideal in the following applications:

  • Additive Manufacturing
  • Die/Mold Industry

EXOCARB® AM-EBT & AM-CRE Inch sizes coming soon!

 

Check out the tools HERE

High Speed Machining

The perfect combination of cutting tool, tool holder, and machine tool takes mold manufacturer to a new level of productivity

Steve Lauman | District Manager

 

For the past 20 years, Lifetime Products Incorporated’s mold shop has been producing aluminum blow molds to support the company’s production of plastic tables, chairs, coolers, kayaks, outdoor sheds, and much more. Lifetime first started its legacy in the sporting goods industry in 1986, introducing a breakthrough basketball system that can be adjusted in seconds. It was the first system that allows basketball hoop homeowners to easily raise and lower the height quickly. Since then, Lifetime has become the world’s largest manufacturer of residential basketball hoops as well as folding tables and chairs, selling products in 58 countries around the globe. Today, the company has grown from 15 employees in a partial warehouse to over 1,500 employees around the world, serving the sporting goods, folding furniture, lawns and garden, playground and the watersports markets.

For the past 20 years, Lifetime Products Incorporated’s mold shop has been producing aluminum blow molds to support the company’s production of plastic tables, chairs, coolers, kayaks, outdoor sheds, and much more.

For the past 20 years, Lifetime Products Incorporated’s mold shop has been producing aluminum blow molds to support the company’s production of plastic tables, chairs, coolers, kayaks, outdoor sheds, and much more.

Lifetime’s global business and manufacturing headquarters is located in Clearfield, Utah, USA. Lifetime’s mold division, which was established in 1999, currently employs 23 staff and has an estimate production area of 16,000-square-feet. As an organization that is committed to innovation and quality, Lifetime is constantly looking for ways to improve their manufacturing process.

For some time, Lifetime has been searching for new solutions to enhance efficiency in their mold production primarily made of aluminum materials such as 6061, 7075 and QC10. In terms of production volume, Lifetime on average produces 20 to 30 molds per year. Lifetime Mold Engineer Dennis Norman and Lifetime Head CNC Programmer Randy Macari are well versed on high speed machining and how it can help them attain much higher productivity. They also understood the required three essential components in order to maximize the benefit of high speed machining – high performance tooling capable of running high speed machining programs, precision holders to secure tool engagement at high rpms, and a machine tool with features such as look ahead software and the ability to run at high speeds.

Lifetime’s mold production is primarily made of aluminum materials such as 6061, 7075 and QC10.

Lifetime’s mold production is primarily made of aluminum materials such as 6061, 7075 and QC10.

The first requirement of high-performance tooling was met when Lifetime began utilizing OSG end mills. Lifetime’s previous tooling choice was a 3/8” 3-flute end mill that was used at 6,000 rpm and 60 ipm. The second requirement was met with OSG’s HY-PRO shrink fit holder and shrink fit technology. OSG’s balanced holder gave Lifetime the ability to mill in excess of 20,000 rpm. The fulfillment of the first two requirements has greatly improved tool life and performance at Lifetime. However, further progress was held back because Lifetime’s older machine tools are incapable of running high speed machining programs. It all changed when this past year, a new Mazak FJV-60/120 vertical mill arrived with look ahead controls designed for high speed machining along with a high-pressure coolant through spindle. With the equipment update, Lifetime is now able to fully leverage OSG’s Exocarb Aero Blizzard high performance carbide end mill.

The Exocarb Aero Blizzard series is a part of the OSG premium line of carbide high performance end mills specifically designed for aluminum and copper alloys. The series’ special end cut gashing and offset teeth permit large depths of cut and maximum feed per tooth. Made with polished flutes to enhance tool life and reduce built up edges, the Blizzard end mill series is engineered to yield high metal removal rates in roughing applications while providing a superior finishing.

The Exocarb Aero Blizzard series is a part of the OSG premium line of carbide high performance end mills specifically designed for aluminum and copper alloys. The Exocarb Aero Blizzard end mill series is available in various end styles, such as square, corner radius and ball.

The Exocarb Aero Blizzard series is a part of the OSG premium line of carbide high performance end mills specifically designed for aluminum and copper alloys. The Exocarb Aero Blizzard end mill series is available in various end styles, such as square, corner radius and ball.

Combined with the new Mazak vertical machining center, OSG’s 3/8” 3-flute Blizzard end mill is now able to reach its full potential, with parameters as high as 15,000 rpm and 220 ipm to generate unparalleled results in productivity. These improvements across all the different milling operations at Lifetime have created an average of 25 percent cycle time reduction. A typical mold is now machined and built in less than 12 weeks, down from an average of 16 weeks. In addition to increased speeds and metal removal rates, Lifetime also saw much improved surface finish, which lowered labor costs by reducing the amount of labor time needed to polish the cavity components of each mold. The combination of a quality tool with precision tool holder engages the workpiece in a more rigid and stable environment, thus resulting in a better surface finish. The overall polishing time was reduced by more than 75 percent. Mold polishing in general added 40 hours to the mold build time, which has now been reduced to eight hours.

Combined with Lifetime’s new Mazak vertical machining center, OSG’s 3/8” 3-flute Blizzard end mill is able to reach its full potential, with parameters as high as 15,000 rpm and 220 ipm to generate unparalleled results in productivity.

Combined with Lifetime’s new Mazak vertical machining center, OSG’s 3/8” 3-flute Blizzard end mill is able to reach its full potential, with parameters as high as 15,000 rpm and 220 ipm to generate unparalleled results in productivity.

 

“OSG’s Blizzard end mill’s performance helped exceed our objectives needed to deliver our molds faster and better,” said Lifetime Products CNC Programmer Randy Macari.

From left, Lifetime CNC Programmer Randy Macari and OSG USA District Manager Steve Lauman pose for a photograph at Lifetime’s manufacturing facility in Clearfield, Utah, USA.

 

High productivity can only be achieved with the perfect combination of cutting tool, tool holder and machine tool. By constantly improving, innovating and leveraging the latest manufacturing technologies, Lifetime will continue its journey in creating affordable and lasting products for consumers and their families.

For more information on OSG’s Exocarb Aero Blizzard series and Lifetime Products Inc.

OSG Announces the Release of PHOENIX® PLDS Indexable Centering and Chamfering Cutter series

We are pleased to announce the release of our NEW OSG PHOENIX® PLDS Indexable Centering and Chamfering Cutter series! The NEW OSG PHOENIX® PLDS is a versatile series of indexable end mills for spot drilling, countersinking & chamfering.

 

The following list numbers are associated with the OSG PHOENIX® PLDS Indexable series:

 

The OSG PHOENIX® PLDS Indexable series offers the following features & benefits:

  • Economical 3-corner insert with both chipping resistance and sharpness
  • Negative axial rake angle that suppresses burrs on the work surface
  • Coolant hole to improve chip evacuation and cooling effect on the cutting edge
  • Two point angle bodies available in 90° or 120°

 

The OSG PHOENIX® PLDS Indexable series is ideal in the following applications:

  • Versatile tool for efficient processing in multiple applications, including centering, hole entry countersinking, V Slotting and corner chamfering
  • Ideal in Steel, Cast Iron, Stainless Steel, Non-Ferrous, HRSA, and Hardened Steel

 

Check out the tools HERE

Complete Chip Control

OIL-S-XPF forming tap enables stable and chip-free tapping in cylinder piston production

Mark Coryea  |  District Manager

 

Saving a few seconds may not sound like much at first, but when you are making over 1 million parts per year, every second counts. Consider what saving 10 seconds per part, reducing scrap rate, shortening final assembly time, all while enjoying three times the tool life could do! This is a reality for Flickinger Industries, a contract machining and manufacturing company in Fort Wayne, Indiana, United States.

Flickinger Industries started in Fort Wayne in 1960 primarily servicing the pump and pneumatic / hydraulic cylinder industries. Today with 45 full-time employees, Flickinger Industries is still leading these industries while also serving customers in the agricultural, automotive and medical fields. Over the years, Flickinger Industries’ personnel have become adept at rapid changeover. Machining small batch parts has become one of the company’s specialties. By utilizing its state-of-the-art 75,000-square-foot facility along with 23 modern CNC lathes and vertical CAT40 machining centers, Flickinger Industries can handle runs from two to 200,000 pieces with ease.

One of Flickinger Industries’ larger customers is a well-known world leader in motion and control technologies. The company has been producing aluminum air cylinder pistons in sizes ranging from 1/2” diameter up to 3” diameter and in lot sizes of typically 2,000 to 5,000 pieces – totaling over 1 million pistons per year. The parts are made from T356 aluminum bar stock and each piston has a threaded center hole. The thread finish needs to be free of smearing and burrs that would hamper assembly. Threading the center hole is challenging because the tool is stationary, while the part is rotating. Flickinger Industries was using a competitor cut tap for many years and became accustomed to periodic catastrophic tap breakage inherent with long chipping materials like aluminum. In early 2019, a breakage damaged a lathe turret, causing excessive downtime and costly repairs. It was at this time that I visited Flickinger Industries with a distributor, and discussed the issues caused by the lack of chip control. The tool being used at that time was a competitor 5/16”-24 cut tap in bright finish, spiral fluted with modified bottoming chamfer in 2B class of fit. I showed Flickinger Industries OSG’s XPF forming tap series and explained how chip control issues would be a thing of the past by utilizing form taps, something the company knew of, but had never thought would remedy to their issue.

Because a forming tap forms screw threads through plastic deformation of work material, no cutting chips are created. With no cutting chips, chip evacuation troubles can be completely avoided. The XPF is OSG’s high performance forming tap that produces no chips and is optimized for machining materials up to 35 HRC. It is uniquely engineered with a low-torque design to facilitate longer life at faster speeds. Its V coating also enables extreme wear resistance. The XPF is available with or without coolant holes, and in standard or long shank style.

After a detailed evaluation of the application, I offered to bring a test tool of the OIL-S-XPF tap under OSG USA’s guaranteed trial order. The XPF tap has been one of my strongest weapons against the competition. It has claimed victory in several materials, competing against every well-known manufacturer in the market. For the machining, Flickinger Industries uses a Mori Seiki SL lathe and WSO emulsion coolant at 12 percent. As anticipated, the trial was a major success. Within the first 10 minutes, the operator commented “That’s twice as fast as the old tap!”

The competitor cut tap required approximately 20 seconds per part, whereas the XPF forming tap only needs 10 seconds. During periodic spot checks for pitch diameter and thread finish, all were well within optimal specifications. Normal tool life for the previous competitor tap was 3,000 pieces, which the XPF achieved and surpassed with ease. Flickinger Industries’ Plant Manager Tom Schroeder said he was ‘…sold on the XPF since we are saving so much time per part.’

The first test tap completed over 14,000 pieces before some slight thread galling was observed, but the tool could still continue to be used. The second test ran just as well as the first, and the next question from Flickinger Industries was “Does OSG make the XPF in 1/2”-20 and 7/16”-20 thread sizes?” And the answer is “Yes, we do!”

Tool life for the OIL-S-XPF is now set at 10,000 pieces as the standard, even though testing has proven that they could carry on further. Nevertheless, the cost per unit dropped from $0.017 to $0.006 per part, enabling an estimate annual cost savings of $37,775. I’m proud to say that today, every aluminum piston made at Flickinger Industries uses taps from OSG’s XPF series. By employing OSG’s XPF forming taps, Flickinger Industries is able to resolve chip control issues, reduce breakage, and avoid future machine damage to maximize performance.  

For more information on OSG’s XPF forming tap series

OSG Featured in Cutting Tool Engineering Article

Give and Take  

Author: Alan Richter

Published: July 2020 - Cutting Tool Engineering Magazine Vol. 72

 

When a workpiece material is relatively easy to machine and a wide range of parts are made of it, a large number of part manufacturers will machine it. As a result, shops must achieve a high level of productivity to remain competitive, and that’s certainly the case with aluminum alloys.

One cutter doesn’t fit all aluminum machining needs, so end users must work with toolmakers that have offerings across the spectrum.

“Because there are such a high variety of parts that are made of aluminum, you have to have a high variety of tools to serve the market,” said Alyssa Walther, automotive specialist for Irving, Texas based OSG USA Inc., who’s based in Bensenville, Illinois.

Playing Flutes

When milling aluminum, the number of flutes on a tool is critical. Walther said a three-flute tool is common and effective for performing conventional roughing and semifinishing. Two-flute tools, however, provide an added benefit when slotting, deep pocketing and even finishing because their design enhances chip evacuation by providing the most amount of flute space.

“If you have a longer overhang and want a really smooth finish, typically the lower number of flutes will

help reduce the amount of cutting vibration because there are only two points,” she said. “You’re basically indexing the tool 180° apart, so it gives the tool a chance to calm the chatter down.”

Although a two-flute tool is more ordinary for milling aluminum, Parker said LMT Onsrud offers three-flute roughers that help lower the considerable spindle load on a machine.

However, two- or three-flute tools are not the only options when cutting aluminum. Walther said end users performing high-efficiency machining, which generally involves running at high feed rates and taking deeper DOCs (step-downs) and a shallow WOC, are gravitating toward tools with four to seven flutes — or more.

“It depends on what the customer’s style of machining is,” she said.

A Lubricious Layer

To help prevent BUE and extend tool life, Matsumoto said OSG USA can deposit a diamondlike carbon coating on tools for aluminum applications.

“We are trying to reduce the friction so we can avoid chip welding on the tools,” he said.

The coefficient of friction for OSG USA’s DLC coating is approximately 0.1.

Tools that cut aluminum commonly are uncoated. In those cases, Matsumoto recommends much polishing of tool surfaces to combat BUE.

 

You can view the original article by clicking here

OSG USA Announces “Shaping Your Dreams” Scholarship Winners

 

St. Charles, IL – May 2020 - OSG USA recognized the recipients of its annual “Shaping Your Dreams” scholarship program, which was created to assist students in fulfilling their educational goals in the fields of machining, manufacturing, and engineering. Jackie Fisher of York Community High School and Kyle L. Townsend of Wadsworth High School each received the $5,000 scholarship toward their education in their chosen fields. Fisher, the Illinois recipient, will be attending Iowa State University in the fall with a major in Mechanical Engineering and a minor in Fashion Design. She has a passion for problem-solving, sewing, and design.  Fisher stood out among many qualified applicants due to her excellent writing skills and creativity. Townsend, the Ohio recipient, will be attending Ohio Northern University in the fall where he will major in Mechanical Engineering and minor in robotics.  He is looking forward to expanding his knowledge and feeding his hunger to learn more about the Engineering field.  Townsend hopes that his passion will help deliver innovation and out-of-the-box thinking to better provide solutions for the needs of a more modern tomorrow. Due to Illinois’ stay-at-home order and social distancing guidelines, OSG USA awarded the recipients via virtual ceremony on May 20th, 2020.

 

LIVE Demonstration of OSG's A Brand® AE-VMS End Mill

 

OSG will be LIVE on YouTube this Thursday demonstrating the A Brand® AE-VMS Carbide End Mill!

Tune in on 6/18 at 11:00 am (CST) by heading over to OSG USA's YouTube page or by clicking HERE