Stable and high efficiency in small diameter deep-hole applications.

- Hiroyuki Amano, OSG Corporation Applications Engineer (Drill Development Division)

OSG Corporation has recently released the ADO-MICRO – the company’s first small diameter carbide drill with oil holes designed for stable and high efficiency drilling in deep-hole applications. The sense of size upon hearing the phrase “small diameter” will be understood differently among users in the manufacturing industry.

The ADO-MICRO has a lineup of drill diameters from 0.7 mm up to 2 mm for drill lengths of 2xD and 5xD, and diameter 1 mm to 2 mm for drill lengths of 12xD, 20xD and 30xD. The product name ADO-MICRO may seem to be associated with the unit prefix micro (µ), but it was named to simply imply smallness in size regardless of the unit.

For small diameter drilling, options such as carbide drills and HSS drills using external coolant are available. However, today’s machining needs require greater stability, higher efficiency and longer life than ever before. There is no exception in small diameter deep-hole applications, with growing needs for coolant-through small diameter drills.

Tool Geometry

One of the keys for successful small diameter drilling is trouble-free chip evacuation. As illustrated in figure 1, chips generated at the tip of the tool flow in the direction of the blue arrow. However, if there is insufficient space in the flute, cutting chips cannot evacuate smoothly, which causes the drilling accuracy to deteriorate and increases the probability of tool breakage. Therefore, by providing a wider flute specification at the area where the tip of the blue arrow locates, as depicted in figure 1, cutting chips are able to be discharged without difficulty, leading to stable machining.

Figure 1. Extended flute

In addition, the ADO-MICRO employs a unique double margin geometry (as depicted in figure 2) in all sizes to enable stable machining even in deep-hole applications. In order to ensure the rigidity of the cutting edge, the margin is set to the minimum necessary length. However, micro sludges can be easily accumulated around the outer periphery of the cutting tool, which is a key cause of abrupt tool breakage. To resolve this challenge and to achieve an overall balance, an extended flute configuration is incorporated to provide sufficient exit room as shown in figure 3.

Figure 2. Four support points with the double margin design

Figure 3. Exit room at end of margin

Oil Holes

The ADO-MICRO features a straight hollow shank design where coolant is injected in addition to the two spiral oil hole paths. This configuration increases coolant discharge from the tool tip. Without the hollow shank configuration, greater pressure is required in order for the coolant to pass through the thin oil hole paths. With the hollow shank feature, pressure loss is reduced, which increases the coolant flow volume. As illustrated in figure 4, with a higher coolant flow rate, cutting chips can be more effectively evacuated, thereby enabling stable machining.

Figure 4. Relationship between shank structure and coolant flow volume

OSG’s Latest Coating Technology: IchAda Coating

Another key element for achieving stable processing in small diameter deep-hole application is coating technology. The role of tool coating is to provide wear resistance and heat resistance to prolong tool life, which is particularly important to small diameter tooling. As illustrated in figure 5, the coating surface by conventional technology is not smooth, which may interfere with the performance of chip evacuation. OSG’s latest IchAda coating, on the other hand, provides excellent surface smoothness in conjunction with high wear resistance and heat resistance to enable small diameter tools to achieve long tool life by improving adhesion.

Figure 5. Surface of coating

Cutting Data

Figure 6 demonstrates a comparison of tool life between the ADO-MICRO and two other tooling manufacturers’ products in the machining of SCM440. The competitor drills have chipped or have broken at the initial machining stage. The ADO-MICRO, on the other hand, was able to achieve long tool life stably due to its superior chip evacuation capability by breaking chips into small and manageable pieces.

Figure 6. Stable and long tool life in SCM440

The ADO-MICRO demonstrates stable performance even in difficult-to-machine titanium alloy applications. As shown in figure 7, the competitor drill struggled with chip evacuation, thus requiring step processing. However, with the ADO-MICRO, step processing can be eliminated while achieving approximately five times the drilling efficiency. The ADO-MICRO was still in good shape after doubling the competitor drill’s tool life, allowing it to be used on other applications.

Figure 7. Efficiency improvement in titanium alloy

The ADO-MICRO’s unique tool geometry and OSG’s original IchAda coating allow non-step drilling even for deep-hole applications, enabling high processing efficiency. By eliminating common complication in small diameter deep-hole drilling, the ADO-MICRO is able to excel with stable performance in a wide range of work materials including stainless steel. In addition to standard stock items, OSG also offers customization services with tailored solutions for each and every manufacturer’s specific machining needs.

For more information: Click Here

The following NEW list numbers are associated with the 

EXOCARB® WXS-CRE End Mills:

• List 4472 - EXOCARB® WXS-CRE (Inch)

• List 4572 - EXOCARB® WXS-CRE (Metric)

 The series offers the following features and benefits:

• Provides advanced productivity with spiral flute design

• Radius end mill for high feed machining

• Ideal for stainless steel and titanium as well as cast iron

• Effective up to 65 HRC steel

• WXS coating, carbide substrate

EXOTAP® VCX Series

Added to List 10051:

• Fractional Sizes (10 edp's)
• Large diameters from 9/16" through 1"

Added to List 11051:

• Metric Sizes (12 edp's)
• Large Diameters from M14 through M24

EXOTAP® A-TAP® Series

 NEW EDPs Have been added to the following List #'s:

A Brand is OSG’s premium tooling brand that represents the quality assurance OSG guarantees to each and every customer. A Brand products (A-Drills, A-Taps and A-End Mills) are designed to exceed the evolving manufacturing needs of our customers. The A-Drill series features EXOCARB^® AD, ADO, ADO-SUS and ADF. Experience the level of quality, reliability and satisfaction that can only be delivered by OSG’s A Brand tooling master class!

EXOCARB^® AD & ADO 2D-30D

The EXOCARB^® AD & ADO feature superior point strength with low cutting force are achieved to accommodate a wide range of carbide drilling applications. EgiAs coating constructed with extreme toughness, high wear and heat resistance characteristics ensure stable and consistent tool life. The EXOCARB^® ADO offers a coolant-through option for those with coolant capabilities.

AD & ADO Features

• EgiAs Coating for exceptional wear resistance and toughness
• Coolant-Through (ADO) for longer tool life and smooth chip evaluation
• Optimized Drill Geometry For Every Drilling Depth
  • Wavy Point Form (2D-8D) reduces thrust and torque while creating smaller more manageable chips
  • Straight Point Form (10D-30D) enhances cutting edge strength while reducing cutting forces
  • Wide Flutes (2D-8D) facilitates stable chip evacuation
  • Middle Margin (8D-30D) improves stability in deep-hole applications

AD Line-Up

• List 6300 – 2D
• List 6310 – 4D

ADO Line-Up

• List 6500 – 3D
• List 6510 – 5D
• List 6520 – 8D
• List 6530 – 10D
• List 6535 – 15D
• List 6540 – 20D
• List 6550 – 30D

EXOCARB^® ADO-SUS 3D & 5D

Work hardening, welding, elongation of cutting chips and poor thermal conductivity are common problems in the machining of stainless steels and titanium alloys. The ADO-SUS is a carbide drill series that employs a unique coolant hole shape and tool geometry to enable efficient drilling in these difficult-to-machine materials.

ADO-SUS Features

• Patented "MEGA COOLER" Coolant Holes drastically increase coolant flow, suppressing heat generation and enhancing chip evacuation
• Patented Flute Geometry forms ideal chips for efficient chip evacuation
• Patented Cutting-Edge Geometry reduces work hardening
• WXL Coating provides superior heat and wear resistance for long tool life

ADO-SUS Line-Up

• List 5200 – 3D
• List 5210 – 5D

EXOCARB^® ADF 2D

Machining a flat hole traditionally required the use of an end mill and a drill. The EXOCARB^® ADF enables one-step drilling to simplify machining time and tool management. Suitable for a wide variety of drilling applications including inclined surfaces, curved surfaces, counterboring, eccentric holes, thin plates, etc.

ADF Features

• EgiAs Coating for exceptional wear resistance and long tool life
• Wide Flutes for superior chip evacuation
• Balanced Point Form for reduced thrust and improved stability
• Improved Cutting Edge reduces cutting forces and creates smaller chips

ADF Line-Up

• List 5700 – 2D

Watch our A Brand video on YouTube!

We are pleased to announce the release of OSG EXOTAP® VC-10 & VA-3 Coolant-Through DIN length Taps for Difficult to Machine Materials and Stainless Steel.

The following list numbers are associated with the EXOTAP® VC-10 & VA-3 products.

• List 317TI - EXOTAP® VC-10 Ti Oil DIN SFT Inch sizes
• List 348TI - EXOTAP® VC-10 Ti Oil DIN SFT Metric sizes
  
• List 317 - EXOTAP® VC-10 Oil DIN SFT Inch sizes
• List 351- EXOTAP® VC-10 Oil DIN SFT Metric sizes
• List 307- EXOTAP® VC-3 Oil DIN SFT Inch sizes
• List 347 - EXOTAP® VA-3 Oil DIN SFT Metric sizes
• List 316TI - EXOTAP® VC-10 Ti Oil DIN POT Inch sizes
• List 347TI - EXOTAP® VC-10 Ti Oil DIN POT Metric sizes
• List 316 - EXOTAP® VC-10 Oil DIN POT Inch sizes
• List 350 - EXOTAP® VC-10 Oil DIN POT Metric sizes
• List 306 - EXOTAP® VC-3 Oil DIN POT Inch sizes
• List 346 - EXOTAP® VA-3 Oil DIN SFT Metric sizes

This series offers the following:

• V Coating for increased harness, lubricity & wear resistance
• Expanded the VC-10 series offering to include both coolant-through and DIN
  overall length options
• The VC-10 series has unique geometries to excel in titanium or other difficult to
  machine materials as does VA-3 which excels in Stainless Steel.
• The VA-3 features HSSE Substrate for increased wear resistance.

OSG PHOENIX® PFR Finishing Radius End Mill series:

The following list numbers are associated with the PHOENIX® PFR products:

List 52200 -- PHOENIX PFR inch end mill bodies

List 78320 -- PHOENIX PFR metric end mill bodies

List 52605 -- PHOENIX PFR inch screw fit bodies

List 78220 -- PHOENIX PFR metric screw fit bodies

List 78PFR -- PHOENIX PFR inserts

What's new?

• Added Ø0.250" end mill bodies and inserts
• Added Ø6mm end mill bodies and inserts
• Added 2.5 L/D Ratio steel shank end mill bodies

 
OSG PHOENIX® PXMC Collets for the PHOENIX® PXM Exchangeable Head End Mill series: 

The following list numbers are associated with the PHOENIX® PXMC products.

List 78340 -- PHOENIX PXMC collets

What's new?

• PXMC collets are available in short and extra-short versions
• PXMC collets are compatible with OSG's HY-PRO Shrink 2pc Base Holders
• PXMC collets dramatically reduce overhang length to greatly improve milling rigidity & balance
• PXMC collets are ideal for use in small machining centers

Please visit our website for product information, pricing and availability.

We announced the release of our new EXOCARB® ADF drills. The ADF combines two operations in one for the drilling of inclined surfaces and counterboring applications.

The ADF was developed with an “all-purpose” concept for superior versatility, reliability and quality for flat-bottom holes. Machining a flat hole traditionally required the use of an end mill and a drill. The ADF enables one-step drilling thereby simplifying machining time and tool management. The drill’s balanced point form improves precision and minimizes the shifting of hole position. Its sharp cutting edge results in low cutting force to minimize burrs even in thin plates. With a wide chip room geometry, trouble-free chip evacuation can be achieved. Furthermore, with the addition of OSG’s new proprietary EgiAs coating, tool life can be prolonged with excellent heat and wear resistance.

The ADF is engineered for a wide variety of drilling applications including inclined surfaces, curved surfaces, counterboring, eccentric holes, thin plates, etc. It is suitable for common materials such as carbon steel, alloy steel, hardened steel (up to 35 HRC) and cast iron. Standard types are available in diameters from 2 to 20 mm; long types are available in diameters from 3 to 20 mm).

By Dustin Loschiavo, District Manager

Did you know there are twice as many people wearing braces today than there were 15 years ago? The need for the new and improved orthodontic products has grown rapidly.  I recently visited American Orthodontics in Sheboygan, WI, one of the largest Orthodontics manufacturers in the world. They have just introduced the PowerScope, a wire to wire device that eliminates the need for headgear and special bands with more comfort and a better aesthetic appearance.

I spoke with Lee Vogel, Manufacturing Engineer at American Orthodontics, who expressed that they were having a problem with tool life on the right and left side tower mounts. They had recently changed materials per the customer’s request from a 316 stainless steel to a 17-4 stainless steel to extend the life of the device. The machining process involved milling a flat on two sides of round stock using a Citizen bar-feeder lathe. They were using a competitor’s 1/8 – 1/8 – 1/4, 1 ½ 4 fluted end mill. This end mill was taking 10 passes per side running at 4500 RPM and a feed rate of 8 IPM. I suggested that Lee should take less passes and test OSG’s Aero UVX end mill (3/16 – 7/16 - 0.015 CR 4 flute) for his new material application. We set up at 4 passes per side running at 5000 rpm and a feed rate of 16 IPM.  This change alone saved 11 seconds per part and the tool life went from 1600 pieces to 6000 pieces per end mill.

As the number of people with braces is expected to increase more in the near future, manufacturers need to keep up with the trends and demands for the improved braces by coming up with new innovations. In order to do so, it is crucial to be flexible and ready to machine any new materials with efficiency. OSG’s Aero UVX end mills changed the game of machining 17-4 stainless steels with efficiency and extended tool life.

*This article originally appeared in the OSG Cutting News Magazine 2015 Medical Edition.

Current Situation

David Whitmire, OSG district manager, has been covering a sales territory in Texas and Oklahoma for 9 years. He has witnessed both the best and worst days of the energy industry. Since the price of oil per barrel has recently reached record lows, our economy and oil field manufacturers have been severely affected. An increasing number of layoffs and downsizing at companies has occurred in the area. During this down time, some oil field manufacturers started to do their homework by reconsidering their machining processes as an avenue to cut costs. This has opened up some new opportunities for OSG in David’s territory.

One of David’s customers is a large pump housing manufacturer in the oil field industry. During the industry slowdown, the company wanted to be proactive, so they invited OSG and a local distributor to host a tap trouble shooting seminar. During the seminar, David showed them the OSG EXOTAP® A-Tap® and EXOPRO® Mega Muscle® drill videos. These videos drew a lot of attention as they showed A-Tap® and Mega Muscle® products surpassing speeds and feeds of competitors’ tools. This company produces 50 to 60 parts after spending over 625 hours machining per month. David decided to perform tool testing with his local distributor to help the company improve productivity and cut costs.

Tool Testing/Solutions

Material: 4140 Modified Alloy Steel

Results

Test 1 demonstrated a significant advantage of the A-Tap®. Even if it ran at the same speeds and feeds with the competitor’s tap, the A-Tap® was able to produce 25% to 40% more pump housings and to reduce costs by $22 per tool versus the competitor’s tap.

Tests 2, 3, 4 and 5 showed that OSG’s taps and drills ran at faster speeds than the competitors’ tools, and the A-Tap®, VXL Tap and Mega Muscle® products were able to reduce the cycle time by 23 minutes. In addition, the A-Tap® and Mega Muscle® machined 5 times more parts than the competitors’ tools did.

Tests 6 and 7 have not been completed, but David is confident that the WDO® drills and PXD drills will reduce the cycle times even more. By using OSG’s taps and drills in their operation, David predicts that the company will be able to reduce at least 21 hours of machining time per month!

Are you struggling with unstable machining with your indexable tools? Higher cutting force is one of the main causes of vibration and instability. You want to achieve lower cutting force to prevent vibration, but you are also looking for ways to improve productivity. OSG’s PHOENIX® PSE (90° indexable shoulder cutter) and PHC (indexable high feed cutter) offer solutions that not only provide lower cutting forces and better productivity, but also enhanced rigidity and improved quality of your finished parts. 

Many conventional shoulder mills have difficulty with ramping and helical milling operations due to their design. OSG's PHOENIX® PSE enables productive ramping and helical milling with the insert's bottom notch feature. The PSE's cutting geometry also generates lower cutting forces, and the insert's wiper edge produces superior surface finish. PSE is a multi-purpose cutter that can tackle a wide range of applications including facing, side milling, slotting, ramping and helical milling! Watch PSE in action!

If you have specific needs for a rough milling application and achieving high metal removal rates, our PHC is the go-to tool for you. A combination of sharp cutting edge and high feed cutting edge design makes it possible to achieve productivity and low cutting force even with overhangs! PHC’s economical 4-corner insert with a chip breaker enhances cutting performance while maintaining rigidity. Watch PHC in action!

For a limited time only, you can save on our high performance indexable milling cutters. Take advantage of our amazing deals to achieve stable milling! Click HERE to learn more about the deals!