FEATURE:
DIAMOND TOOLINGOSG GLOBAL TOOLING MAGAZINE I WINTER 2023

The strongest tools, made from theearth’s hardest mineral

TECHNICAL INSIGHTGLOBAL REPORTS

OSG NEWSEMPLOYEE INTERVIEW

AE-LNBD-N DLC Coated
End Mill for Copper
Electrode Applications

Italy
USA
Germany

INTERMOLD 2022
New Taipei Office
Germany Benchmark Eventin Thailand

2023 - a year of decisive test for“Beyond the Limit”
A Message from the President
The initial shock of the unpredictable long-term global
impact caused by the COVID-19 pandemic has now
passed. The world economy has resumed economic
activities amid the COVID-19 crisis and is now facing
new challenges such as rising energy and material costs,
inflation, and chronic shortages of goods. There is notime to stand still in such a fast-paced era.
Since the pandemic, OSG has been confronted withnumerous challenges due to the sudden changes inmarket conditions and disruptions in the supply chain.
Under such circumstances, the formulation of OSG’s
new medium-term management plan “Beyond theLimit 2024” and business reforms could not have beentimelier. In OSG’s medium-term management plan,
the company aims to improve business efficiency andstrengthen its corporate structure so that profits canbe generated at all times. Fostering a strong corporate
structure that can withstand the impact of socialchanges will ultimately contribute to the creation of asustainable society in the future.
For the medium-term management plan that beganfrom fiscal 2022, several business strategies have alreadybeen implemented. In particular, sales of “A Brand
products,” which contribute to the expansion of market
share, and a greater emphasis on the “micro precisionsector,” which is positioned as a new strategic market, areprogressing steadily. Based on these pillars, OSG sees fiscal 2023 as a critical year for the global expansion of these strategies
and achieving the medium-term management plan.
To achieve new goals, one must challenge the status quo, setting no limit, and to break through conventional wisdom. Thereis often a tendency to resist change unless major problems arise. It is important to always have doubts regarding the existing
condition. OSG will strive to continuously evolve with new innovations to provide products and services that satisfy ourcustomers. Moving forward, OSG will make every effort to become an “essential player” (indispensable manufacturer) that
contributes to the global manufacturing industry.
Lastly, I would like to wish our SHAPE IT readers a happy and prosperous new year.

Nobuaki Osawa
President & COO of OSG Corporation

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SHAPE IT   ﻿CONTENTS Feature
SHAPE ITWINTER 2023

3 Diamond ToolingTechnical Insight
9 AE-LNBD-N DLC Coated End Mill for Copper Electrode Applications

Customer Report
13 One Pass Threading
17 High-efficiency Milling in Inconel 718
19 Adding Values

Product Pickup
21 AT-2 R-SPEC Thread Mill, AE-VTSS Anti-vibration Carbide End Mill
22 AE-CPR4-H 4-flute Long Neck Corner Radius Carbide End Mill,PXSH Exchangeable Head End MillOSG News
23 INTERMOLD 2022, New Taipei Office
24 Benchmark and Networking Event in Germany

Meet OSG
25 Employee Interview in Thailand

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: January 2023
Rights: Reproduction of the articles and photographs without permission is strictly prohibited.

OSG Corporation International Headquarters
3-22 Honnogahara, Toyokawa, Aichi 442-8543, Japan Tel: (81) 533-82-1111 Fax: (81) 533-82-1131 www.osg.co.jp

SHAPE IT   ﻿

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Diamond Tooling
The strongest tools, made from the earth’s hardest mineral
Nanami Kaito
Nissin DiamondDiamond Tooling
A diamond tool is a cutting tool with diamondgrains fixed on the functional part of the tool bymethods such as brazing. There are numerous kindsof diamond tools available in the market and they are
categorized by manufacturing methods and usage.
Diamond is made of the hardest mineral on earth
with outstanding hardness, strength, and chemical
stability (at temperatures of 600 K or less) and afriction coefficient of 0.1 or less. These properties
result in extremely high accuracy compared to
cutting tools made from other materials. Moreover,diamond tools can be repolished with sharpened

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SHAPE IT   Feature

cutting edges, making them an environmentally friendly
tool option.
Diamond tools are ideal for the processing of
non-metallic materials and non-ferrous metals due totheir excellent hardness and diffusion of heat properties.
Diamond tools are commonly used in industries including
IT, home appliance, construction machinery, automotive,
aerospace, medical equipment and more. In recent
years, diamond tools are especially in demand for theprocessing of optical components and metal molds thatare small, require ultra-precision and mirror surface finish.

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Diamond Tooling by Nissin Diamond
Nissin Diamond Co., Ltd. is a cutting tool manufacturer
based in Takashima, Shiga, Japan. Nissin Diamond has
been active in the development, production and salesof diamond cutting tools since the company’s founding
in 1968. In September 2006, Nissin Diamond became aconsolidated company of OSG Corporation.
Nissin Diamond specializes in the production and salesof natural diamond cutting tools, synthetic single-crystal
diamond cutting tools, polycrystalline diamond (PCD)
cutting tools, and polycrystalline cubic boron nitride(PCBN) cutting tools.

3

1. Nissin Diamond Co., Ltd. is a cutting tool
manufacturer based in Takashima, Shiga,
Japan. Nissin Diamond has been active in thedevelopment, production and sales of diamondcutting tools since the company’s founding in 1968.
2. Nissin Diamond’s operators prepare for themachining of new products. Nissin Diamondspecializes in the production and sales of natural
diamond cutting tools, synthetic single-crystal
diamond cutting tools, polycrystalline diamond(PCD) cutting tools, and polycrystalline cubic boron
nitride (PCBN) cutting tools. Nissin Diamond’s
products are used in a wide variety of industries
including IT, home appliance, construction
machinery, automotive, aerospace, medical
equipment and more.
3. Nobuaki Kamiya, CEO of Nissin Diamond,poses for a photograph at the company office inTakashima, Shiga, Japan.

SHAPE IT   Feature

4Natural Diamond Cutting Tools
Natural diamonds are formed in the earth’s mantle when carbon crystallizes
over the course of billions of years at extremely high pressure and temperatures.
Natural diamond provides the best sharpness for cutting blades. As a natural
product, the quality of these diamonds can vary considerably. However, theunparalleled sharpness they provide as cutting blades is indispensable in theultra-precision machining of items such as molds for aspherical lenses.
Natural diamond cutting tools are primarily used for finishing in aluminum
applications. The diamond can be brazed to an existing indexable insert or a
carbide tool body. Natural diamond cutting tools leverage the characteristics of
diamond to improve the accuracy of work pieces used in micro andultra-precision machining.

Synthetic Single-crystal Diamond Cutting Tools
Synthetic diamond is manufactured by crystallizing carbon-based components
under strict quality control at high temperature and high pressure conditions.
Since this substance is created by the work of humans, supply is more stable
than natural diamond. In addition, although synthetic diamond has thesame chemical structure as natural diamond, it is a stable crystal with
few impurities, defects, and distortion, enabling consistent cutting
performance.
Natural and synthetic single crystal diamond cutting tools are
manufactured by special brazing and polishing techniques. They are
effective for machining that requires stable quality and tool life, such as
highly transparent resin machining, optical parts, and precision machining of
automobile-related parts.
Surface Roughness Comparison in Aluminum Alloy

The image on the left is a workpiece machined by a PCD tool with asurface roughness of Ra 300 n. The image on the right is a workpiecemachined by Nissin Diamond’s synthetic single crystal diamondcutting tool with a surface roughness of Ra 50 n. The workpieceby the single-crystal diamond cutting tool exhibits a shiny surface
finish, whereas the surface by the PCD tool measures six times higher
roughness. Nissin Diamond’s synthetic single crystal diamond cutting
tools are effective for machining that requires stable quality and longtool life, such as highly transparent resin machining, optical parts,and precision machining of automobile-related parts.

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SHAPE IT   Feature

Nissin Diamond synthetic single-crystal
diamond inserts in various shapes and sizes.

Polycrystalline Diamond (PCD) Cutting Tools
Similar to synthetic single-crystal diamond, polycrystalline diamond(PCD) is another type of diamond. PCD cutting tools are most commonlyused in non-ferrous and non-metallic materials. As performance inautomotive component improves, better aluminum alloys and improved
tool performance are also required. PCD tools provide consistent
precision and longer tool life than that of carbide tools. In addition tohaving excellent durability, PCD cutting tools improve the quality ofparts and significantly reduce costs across the entire production cyclewith faster cutting speed.

Nissin Diamond offers polycrystalline diamond (PCD) cutting
tools in a wide range of variations.

Polycrystalline Cubic Boron Nitride (PCBN) Cutting Tools
Polycrystalline cubic boron nitride (PCBN) is an artificial mineralconsisting of nitrogen and boron that does not exist in nature. CBN
powder is made by treating hexagonal boron nitride (HBN) at hightemperature and pressure. The PCBN sintered body is baked at hightemperature and high pressure together with binders such as cobalt
and TiN. PCBN cutting tools are suitable for machining iron-based metalmaterials such as hardened steel, cast iron, and sintered metal, which
are difficult to machine with diamond tools. PCBN tools also offer higher
speed, precision and tool life than carbide tools.
PCBN does not oxidize in the atmosphere up to 1300-celcius whereas diamond
begins to graphitize at 700-celcius. Due to this characteristic, PCBN does notreact with iron. PCBN is second only to diamond in terms of hardness andthermal conductivity, making it a great fit for machining alloy steel and cast ironof 45 HRC and above.
Diamond and PCBN tools can provide exceptional performance, precision and longtool life in many work applications. Nissin Diamond will strive to further enhance its
ability in terms of cost, delivery time, quality, and actively promote the developmentof new proprietary technologies to respond to evolving market needs.

SHAPE IT   Feature

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About Nissin Diamond

Nissin Diamond’s factory in Takashima, Shiga, Japan.

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SHAPE IT   Feature

Nissin Diamond Co., Ltd. is a cutting tool manufacturer basedin Takashima, Shiga Prefecture, Japan. Nissin Diamond has
been active in the development, production and sales of
diamond cutting tools since the company’s founding in
1968. Nissin Diamond specializes in the production and salesof natural diamond cutting tools, synthetic single-crystal
diamond cutting tools, polycrystalline diamond (PCD) cutting
tools, and polycrystalline cubic boron nitride (PCBN) cutting
tools. Nissin Diamond’s products are used in a wide variety
of industries including IT, home appliance, construction
machinery, automotive, aerospace, medical equipment andmore. Many items used in daily life are machined using Nissin
Diamond tools. In September 2006, Nissin Diamond became
a consolidated company of OSG Corporation. Currently
employing approximately 45 employees, Nissin Diamond’s
headquarters and its Aiba Factory are located in Takashima in
the northwestern part of Lake Biwa, Japan’s largest freshwaterlake.

Official Brand Mascot Daiyan
Daiyan is Nissin Diamond’s official
brand mascot. It is a fictional cutting
tool character based on the imageryof a diamond cutting tool, which isa core product of Nissin Diamond
since its founding in 1968.
The friendly diamond cutting tool
character Daiyan serves as Nissin Diamond’s
brand ambassador in the promotion of the company,
the manufacturing industry, and local communities.

The OSG GroupOSG Corporation has individual production facilities
for designated tooling lines including taps, HSS drills
and end mills, carbide drills and end mills, rolling diesand gauges, tool coating, and machine tools.

In addition to OSG’s own product lineup, OSG also
fulfills customer needs with its domestic groupcompanies specialized in their respective fields.
Each domestic group company manufacturers
and sells the products they specialize in. Together,
they offer a broad lineup of products and services,
including the manufacturing of carbide materials
and cutting tools, coating and regrinding services,
as well as sales of machinery. They also offer
various custom services, ensuring that each andevery client will always receive products that suit
their desired processing environment.
Internationally, OSG has a global network of over
65 business offices in 33 countries, which provides
its production sites with accurate feedback aboutuser needs so that the company can quickly
design, develop, manufacture and deliver productsthat precisely meets those needs.

2

1. Nissin Diamond’s operators pose for a photographat its factory. Currently employing approximately 45
employees, Nissin Diamond’s headquarters and its
Aiba Factory are located in Takashima in thenorthwestern part of Lake Biwa, Japan’s largest
freshwater lake.
2. Nanami Kaito, Nissin Diamond Customer Service
Representative, poses for a photograph at the company
factory in Takashima, Shiga, Japan.

SHAPE IT   Feature

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AE-LNBD-N DLC CoatedCarbide End MillHigh precision and excellent surface finish in copper
electrode applications
Hayato Tsuneoka
OSG Corporation Applications Engineer(End Mill Development Division)

The AE-LNBD-N DLC coated long neckball end mill is the latest addition to
OSG’s non-ferrous material processing
end mill series. The AE-LNBD-N isdesigned for the milling of copper
electrodes or copper tungsten electrodes
used in die-sinking electrical dischargemachining (EDM). Its specifications
are uniquely engineered to enable themilling of beautiful copper electrodes
without burrs, which is an indispensable
element for today’s die and moldmanufacturing that emphasizes on“high precision” and “high quality.”

9

SHAPE IT   Technical InsightThe development and globalization of manufacturing
technology has progressed at a rapid pace in recent
years, and the same can be said for the die and moldindustry. According to the International Special
Tooling & Machining Association (ISTMA), the world’s
die and mold production value increased by about
30 percent from 2008 to 2016. With the passage oftime, Japan, which used to hold the world’s largest die
and mold production value, has fallen in production
value since the Lehman financial crisis in 2009, andhas since given up the world’s number one position
to China. On the other hand, in China, supported by aremarkable economic development and an increase in
the number of automobiles produced, the production
value in 2016 was estimated to be 25 billion dollars,
which has almost doubled since 2008.
Copper electrode or copper tungsten electrode,which is the main target material of the AE-LNBD-N,
is commonly used for the manufacturing of plastic
molds. Today, most of the production of plastic dies
has moved from Japan to China and other Asian
countries. Even so, however, plastic dies still makeup about 30 percent of the die production value inJapan, ranking second after press dies. Most of theplastic molds that require high precision are made inJapan, which offers excellent technical capabilities
and quality assurance. The design of the final plastic
product is becoming more complicated and smaller
in recent times. As the molds are becoming “higher
precision” and “higher quality,” a demand for thecopper electrodes used for die-sinking EDM tobecome “higher precision” and “higher quality” hasalso increased.

SHAPE IT   Technical Insight 10

“High precision” and “high quality” in copper electrodes mean high shape accuracy, little dimensional changes evenafter long hours of processing, excellent machined surface roughness, and being burr-free. To meet the needs oftoday’s electrode machining, OSG’s AE-LNBD-N is engineered with a “sharp cutting edge” that realizes excellent
work surface quality, a “high ball radius accuracy” that enables high precision electrode machining, and “highdurability” capability that suppresses tool wear, generation of burrs and changes in dimension even after longhours of processing.

Sharp Cutting Edge
As shown in figure 1, the quality of the primary relief surface is improved compared to the competitor product.
The ridgeline of the cutting edge is sharpened, and this sharpness enables the realization of excellent work
surface quality.
（μ m）0.6■ Ra■ Rz ■ Ra

Competitor

AE-LNBD-N

Competitor

■ Rz

0.4
Surface Roughness

AE-LNBD-N

Surface Roughness（μ m）0.6

0.4

0.2

0.2
0

0

AE-LNBD-N

Competitor

AE-LNBD-N

Competitor

Figure 1. Surface roughness comparison between the AE-LNBD-N and a competitor product.

High Ball Radius Accuracy
As depicted in figure 2, the AE-LNBD-N is engineered with a higher ball R accuracy than conventional products,
which enables the processing of highly accurate electrodes.
RE

0.05

AE-LNBD-N
Conventional

0.075

0.1

0.15

0.2

0.25

0.3

0.4

+/- 0.002 mm

0.5

0.75

+/- 0.003 mm+/- 0.005 mm

Figure 2. Comparison of tolerance of the radius between the AE-LNBD-N and conventional products.

11 SHAPE IT   Technical Insight

1

1.5

2

3

+/- 0.004 mm

High Durability
The AE-LNBD-N is coated with OSG’s DLC-IGUSS, which has high hardness and excellent wear resistance. As
illustrated in figures 3 and 4, the DLC-IGUSS coating exhibits overwhelming wear resistance performancecompared to CrN coating and Cr-based coating, which are often used for processing steel materials.
In addition, by minimizing the progress of wear during long-hour machining, maintaining a “sharp cuttingedge” and “high ball radius accuracy,” it is possible to suppress the occurrence of burrs and dimensionalchanges for a long period of time compared to conventional products as depicted in figures 5 and 6.

AE-LNBD-N

Conventional（mm）0.035

0.030

Flank Wear

0.025
0.020

Figure 5. The AE-LNBD-N achieves good edge without burrs.

0.015
0.010
0.005

（μm） 5.5

70

140

210

280

Milling Length

DLC-IGUSSCrN Coating

350

420

490

Amount of Change in Milling Width0（m）Cr-based Coating

Figure 3. Comparison of milling length and flank wear.
DLC-IGUSSCrN Coating

Cr-based Coating

4.5
3.5
Less than 1/10
in variation

2.5
1.5
0.5
0.0
-0.5

10

20

Before Processing

30

AE-LNBD-N

Figure 4. Wear condition of ball flank after milling 420 m.

40

50

Milling Length

60

70

（m）

Conventional

Figure 6. Comparison of dimensional change after milling morethan 60 m. The AE-LNBD-N demonstrates stable machining
accuracy with little dimensional change, with less than 1/10 invariation versus the conventional product.

The demand for “high precision” and “high quality” in the die
and mold industry is increasing year by year, and it is expectedthat this trend will continue to progress in the future. With
excellent accuracy and durability, the AE-LNBD-N will becomea new standard in copper electrode processing.

Scan for details

SHAPE IT   Technical Insight 12

To solve the problems of deflection and long cycle time, OSG has developed the AT-1, a revolutionary 1-pass thread mill for high-quality
threading, with two patented technologies registered in Japan for its tool geometry.

One Pass Threading
AT-1 thread mill creates high quality threads in one pass without chatter and deflection in
hydraulic component production
Andrea Severi
OSG Italia
Time savings in the machining of hydraulic components
can significantly reduce overall production cost evenin small batches. Eliminating double passes, chatters,
harmonics, and taper of threads were the objectives of
Walvoil S.p.A. in its production of hydraulic components.
Founded in 1973 and headquartered in Reggio Emilia,
Italy, Walvoil is a global manufacturer of integrated
products, electronics, and complete mechatronics
systems. Since 2015, Walvoil has become a part of theInterpump Group. In 2016, Walvoil added two brands
to its group, Hydrocontrol and Galtech, which were
founded in 1969 and 1953 respectively. The Walvoil
group has eight facilities within Italy, seven of which areequipped with manufacturing capabilities. The company

13 SHAPE IT   Customer Report

also has eight foreign branches and a total of 2,300
employees globally.
Walvoil’s core products include hydraulic components
such as distributors and hydraulic servo controls,
pumps and motors, compact hydraulics, electronic
components and PHC systems. Walvoil’s headquarters,commercial and production site in Via Adige, Reggio
Emilia is equipped with 32 numerical control machining
centers, enabling the company to efficiently optimize
work cycles in various batch sizes and materials, such asaluminum, steel and gray cast iron, vermicular cast ironand nodular ductile iron.

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1. Walvoil’s headquarters, commercial and production site in Via Adige, Reggio Emilia, Italy.
2. Walvoil uses a MCM MP10 horizontal machining center for the production of hydraulic distributors.
3. From left, Walvoil NC programmer Egidio Lemmi, OSG Italia Sales Engineering and Marketing Manager Andrea Severi and Walvoil ToolingManager Davide Cabassi pose for a photograph with the AT-1 thread mill at Walvoil’s manufacturing facility in Via Adige, Reggio Emilia, Italy.

Walvoil was experiencing problems of chatter, tapered
threads, bad surface finish and poor tool life in the
production of DLS8 hydraulic distributors made of
EN-GJL-300 cast iron using a competitor threadmill that is 14 mm in diameter, Z4 and with internal
coolant. The part has two G3/4-14 gas threads at an apof 18 mm. Walvoil has been manufacturing the DLS8
hydraulic distributors since 1996. Batches of several
thousand pieces are made annually.
In hopes to optimize cycle time, increase tool life
and improve the quality of threads, Walvoil’s ToolingManager Davide Cabassi reached out to OSG Italia forsupport. Upon a detail evaluation of the application,
OSG recommended a diameter 15.67 mm
AT-1 thread mill (EDP# 8331087).

vulnerable to deflection as the cutting process begins
from the tip. In contrast, the AT-1’s right-hand cut andleft-hand helix geometry begins the cutting processfrom the shank side, thereby minimizes deflection. The
second patented technology is the unequal spacing
and variable lead flute geometry, which is commonly
applied in end mills. The unequal spacing and variable
lead flute geometry minimizes chatter. Even though
the amount of cut has increased with one pass cutting,superior and consistent surface finish can be achieved.
Applying the unequal spacing and variable leadflute geometry in thread mills involves a high degreeof difficulty because the thread pitch has to beenadjusted accordingly to the flute geometry, which
requires special manufacturing techniques.

To solve the problems of deflection and long cycle
time, OSG has developed the AT-1,
a revolutionary 1-pass thread millfor high-quality threading, with twopatented technologies registered inJapan for its tool geometry. The firstpatented technology is the AT-1’s
left-hand helix geometry. Conventionalright-hand helix thread mill is most

SHAPE IT   Customer Report 14

OSG’s AT-1 thread mill was tested at Walvoil’s Via Adige
facility using a MCM MP10 horizontal machining center.
The tool was mounted on a 140 mm long HSK-63 tool
holder with an ER-32 collet.

The AT-1 was tested at Walvoil’s Via Adige facility usinga MCM MP10 horizontal machining center. The tool was
mounted on a 140 mm long HSK-63 tool holder with
an ER-32 collet. The total presetting was 192 mm. In
terms of cutting condition, the competitor thread mill
was used at a cutting speed of 1,000 min-1 and a feed
rate of 150 mm/min, completing a thread in two passes.
The AT-1, in comparison, was used at a cutting speed of
2,200 min-1 and a feed rate of 250 mm/min, completinga thread in a single pass. The AT-1 was able to complete
2,645 pieces versus the competitor’s 470 pieces,achieving more than five times the tool life.
1

With capabilities to complete threading in a single
pass and at higher speeds and feeds, the AT-1 is able
to generate an annual cost savings of 62 percent for
Walvoil. The problems of chatter and deflection havebeen completely eliminated. Moreover, the quality of
thread is optimal and complies with the UNI-ISO 228/1
standard.
With great satisfaction, Walvoil has extended theAT-1 thread mill to other similar applications with
1/2 gas threads. The AT-1’s unique features made it
possible to machine under unstable conditions withincreased reliability, surface finish and accuracy. With
the AT-1’s capability to generate threads in one pass athigh cutting parameters, it is an optimal thread milling
solution that can generate significant cost savings for
manufacturers.

15 SHAPE IT   Customer Report21. Inside Walvoil’s factory in Via Adige, Reggio Emilia, Italy.
The Walvoil group has eight facilities within Italy, seven ofwhich are equipped with manufacturing capabilities. The
company also has eight foreign branches and a total of 2,300
employees globally.
2. Pieces of hydraulic distributors being unloaded on a roller
conveyor on the MCM MP10 horizontal machining center.
3

3. A hydraulic distributor mounted on the locking
equipment.
4. A hydraulic distributor made of EN-GJL-300 cast iron.

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SHAPE IT   Customer Report 16

From left, Allied Tool & Die CNC Process and Machining Manager Jamie Lerma, CNC Machinist David Dao and CNC Programmer John
Hernandez.

High-efficiency Milling inInconel 718
VGM end mill boosts productivity and lowers cost per part in aerospace bracket
application
Sean McIntosh
OSG USAFounded in 1951 in Phoenix, Arizona, United States,
Allied Tool & Die Co. is a family-owned precision
machine and fabrication company that specializes in the
manufacturing of quality parts for aerospace, medical,
communications and commercial industries throughout theworld. Seventy years since its establishment, this privately
owned shop has grown with multiple facilities and an
estimated 32,000 square feet of manufacturing space in
Phoenix, Arizona.
One of the challenges Allied Tool & Die faced recently was themachining of aerospace brackets made of Inconel 718. As iswith most shops, machining Inconel 718 is time consuming.
Moreover, due to the material’s special high strength and heat
resistance properties, short tool life is a common obstacle.

17 SHAPE IT   Customer Report

In search for performance improvement, Allied Tool & Die
CNC Process and Machining Manager Jamie Lerma reached
out to his local OSG representative for new solutions. Lerma
had worked with OSG previously on a 13-8 stainless steel
application by utilizing OSG’s HY-PRO® CARB VGM series end
mill to achieve high-efficiency milling.

12

1. CAD / CAM model of a part made from 13-8 stainless steel. Image
courtesy of Allied Tool & Die.
2. CAD / CAM model of an aerospace bracket made from Inconel 718.
Image courtesy of Allied Tool & Die.

OSG’s HY-PRO® CARB VGM is a high performance variable geometry end
mill series. The VGM offering features 5-, 6- and 7-flute lineups, and isavailable with multiple lengths of cut, with both square end and cornerradius variations. This series is suitable for carbon steels, alloy steels,
die steels, stainless steels, cast iron, nickel alloy, titanium, and hardened
steels up to 45 HRC.

OSG’s HY-PRO® CARB VGM is a high performance variablegeometry end mill series. Its variable index and unique flute
geometry enable the reduction of vibration and chatter,promoting smooth and stable cutting with low cutting
forces. With the addition of OSG proprietary multi-layer
EXO coating, higher wear and heat resistance is achieved
to prolong tool life. OSG’s VGM offering features 5-, 6- and7-flute lineups, and is available with multiple lengths of cut,with both square end and corner radius variations. This series
is suitable for carbon steels, alloy steels, die steels, stainlesssteels, cast iron, nickel alloy, titanium, and hardened steels
up to 45 HRC.
For the 13-8 stainless steel application, the VGM end milldominated the machining result by extending tool life
from seven parts to 21 parts per tool. The parts were also
completed in half the time and the tool cost is also cheaper
than the competitor tool. Lerma was so impressed by the
VGM end mill that he decided to apply the tool to theInconel 718 aerospace bracket application.
Allied Tool & Die was previously using a high feed indexable
milling cutter for the Inconel 718 aerospace bracket
application. However, the amount of time and money spenton changing the inserts was less than desired. The previous
competitor tool was used at 150 SFM (45.7 m/min), 0.009 IPT(0.23 mm/t), 0.05 Aa (ap = 1.27 mm) and 0.75 Ar(ae = 19.05 mm). After reprogramming to utilize OSG’s
0.5-inch diameter 5-flute VGM carbide end mill with a
0.030-inch (0.762 mm) corner radius and 1.25-inch(31.75 mm) length of cut (EDP# VGM5-0143), the cutting
parameters were changed to 250 SFT (76.2 mm/min,
2,548 min-1), 0.0022 IPT (0.056 mm/t, 713 mm/min), 0.75 Aa
and 0.035 Ar. The application went from a 4-hour cycle timeto just one hour and 45 minutes. Allied Tool & Die no longer
had to keep stopping the machine to rotate or change
inserts, which they were doing four times per part previously.
By switching to the VGM end mill, the tool was loaded, andthe job did not have to be tended to until the part wascompleted. In terms of efficiency improvement, Allied Tool

& Die estimated that the tool change has generated acost savings of $6,875 USD on the Inconel 718 aerospacebracket parts. Moreover, with a lower tooling priceversus the previous milling cutter, the cost of tooling also
decreased by almost $100 USD per part. With the
VGM end mill, Allied Tool & Die was able to machine
Inconel 718 at an astounding 250 surface feet per minute(76.2 m/min) – a speed that is only commonly seen inalloy or stainless steels, not HRSA materials.
With the recent successes, Allied Tool & Die’s CNC
Programmer John Hernandez decided to apply the
VGM end mill into most jobs he programs. Being such a
versatile tool, the VGM can be used to machine anythingfrom common carbon steels up to the nickel alloys
required by the aerospace industry.
“This VGM end mill saved us a ton of time,” said Allied Tool
& Die CNC Process and Machining Manager Jamie Lerma,
who has started ordering the VGM series end mill to keep
in inventory for whatever job comes up.

34

3. A part made from 13-8 stainless steel that was machined by OSG’s
HY-PRO® CARB VGM end mill.
4. An aerospace bracket made from Inconel 718 that was machined by
OSG’s HY-PRO® CARB VGM end mill.

SHAPE IT   Customer Report 18

Adding Values
AE-VML anti-vibration long carbide end milldemonstrates stable tool life and reduces toolingcost in secondary process after metal additive
manufacturing of Inconel aerospace workpiece

The AE-VML long typeend mill is a part of the
AE-VM anti-vibration
carbide end mill series
designed to attain an
all new level of milling
efficiency coupled withsuperb finish quality
suitable for a variety of
milling applications.

Magnus Hoyer
OSG GmbH
Inconel is a high-strength, corrosion-resistant nickel alloy thatis commonly used in aerospace applications. Milling complex
parts made of Inconel is a difficult and costly machining
process due to the material’s high tensile strength, which canwear off cutting tools quickly, resulting in high wear rates,chipping and breakage. In addition to shortened cutting
tool life, material loss is also a prominent problem whereparts would warp due to effects caused by residual stresses
and self-hardening during machining. In recent years, metal
additive layer manufacturing has become a new alternative
to the traditional manufacturing method of machining
Inconel parts. Rather than removing materials, additive
manufacturing builds a component layer-by-layer, whichallows greater design freedom in terms of part complexity.
Moreover, additive manufacturing eliminates material wasteof expensive superalloys through nondestructive construction,
improving overall efficiency and cost savings. However, newmanufacturing method also comes new challenges. The
secondary process after metal additive manufacturing has very
many similarities to the milling of built-up welding parts, which
can be tough on the cutting tools and is time-consuming.
PARARE GmbH, a part manufacturer specialized in additive
metals and plastic processing, was recently seeking to improvethe milling process after metal additive manufacturingof highly complex Inconel workpieces for the aerospaceindustry. Established since 2017, the Baden-Württemberg,
Germany based company is an expert in the use of additivetechnologies. PARARE manufactures highly innovative
components for a wide variety of industries made of materials
such as aluminum alloys, stainless steels, titanium, Inconel, toolsteel and plastics.
The additive manufactured bionic structures in question are
made of Inconel 625 and Inconel 718 and aluminum. The batch
size typically ranges from a single piece to approximately
50 pieces. The parts are milled by a Hermle 5-axis machining
center with HSK-A63 spindle.
19 SHAPE IT   Customer Report12

1. Additive manufactured clamping arm
built for transporting engine parts in theautomotive industry. These additive parts offer
significant advantages versus conventional
manufacturing methods with much improved
strength-to-weight ratio.
2. An aerospace part made by PARARE. PARARE
manufactures highly innovative components
for a wide variety of industries made ofmaterials such as aluminum alloys, stainlesssteels, titanium, Inconel, tool steel and plastics.

From left, OSG Germany Technical Sales Representative Bruno Göpfrich, PARARE Head of Production Michael Meyer and PARARE Managing
Director Sven Skerbis pose for a photograph at PARARE’s manufacturing facility in Frickenhausen, Baden-Württemberg, Germany.

PARARE was originally using a competitor solid carbide
end mill for the application. However, performance wasunstable, and the unit price was very high. PARARE initiallydid not know about OSG’s cutting tools. However, when
Michael Meyer joined PARARE as the head of production in
September 2020, Meyer decided to test a few of the OSG
cutters since he had positive experiences in the past withthe company. After a detail evaluation of the application,
OSG Technical Sales Representative Bruno Göpfrich broughtin OSG’s AE-VML (dia. 16 x 64) for the cutting trial.
The AE-VML long type end mill is a part of OSG’s
AE-VM anti-vibration carbide end mill series designed
to attain an all-new level of milling efficiency coupledwith superb finish quality suitable for a variety of milling
applications. The AE-VM’s sharp positive rake angle
geometry significantly reduces cutting force to minimize
tool wear and potential damage to the workpiece evenunder aggressive cutting conditions. Cutting vibration isminimized with the AE-VM’s unequal spacing of teeth andvariable-lead geometry. Furthermore, its unique flute form
helps facilitate trouble-free chip evacuation to enable stable

and consistent performance. With the addition of OSG’soriginal DUARISE coating, tool life can be enhanced by its
excellent lubricity, superior friction-resistance and highoxidation temperature qualities. Available in a wide variety
of styles and specifications, the AE-VM series is designed
to accommodate a wide range of milling operations
in stainless steel, cast iron, carbon steel, alloy steel andhardened steel.
The cutting trial was a major success. Due to confidentiality
reasons, the cutting conditions cannot be disclosed.
However, OSG’s AE-VML is able to achieve more than twice
the tool life and reduce tooling costs by five times versus theprevious competitor tool.

SHAPE IT   Customer Report 20

AT-2 R-SPEC
Thread Mill for Non-ferrous Metals

Nicknamed “ThreadRacer,” the AT-2 R-SPEC
thread mill is designed to dramaticallyreduce machining time in non-ferrous metal
applications such as aluminum alloy by its
continuous helical cutting ability, which
combines drilling and threading into a single
process. The AT-2 R-SPEC is also effective asa countermeasure against cutting position
misalignment in cast holes.

distribution is achieved by its roughing teeth
geometry. Moreover, the AT-2 R-SPEC’s 2-flutewide chip room configuration and oil holeallow for superior chip evacuation (applies
to dia. 4.6 mm or more). With the additionof OSG’s DLC-IGUSS coating, long tool life
can be achieved in non-ferrous metals suchas aluminum alloys that require welding
resistance and lubricity.

The AT-2 R-SPEC features a left-hand cut
configuration for climb milling toprolong tool life. Higher
efficiency by load

AE-VTSS
Anti-vibration Carbide End Mill Compatible with Sliding Head Lathes

The AE-VTSS is optimally designed toaccommodate sliding head lathes, featuring
an overall length of 50 mm or less and a lengthof cut of 1.5 x D or less. The AE-VTSS’ 3-flute
specification and bottom cutting edge hookshape contribute to the creation of stablechip shape and improve chip evacuation.
Chattering is minimized by the AE-VTSS’unequal spacing of teeth and variable-leadgeometry to enable stable and high-efficiency
milling. With the addition of OSG’s original
DUARISE coating, tool life can be enhanced by
its excellent lubricity, superior

21 SHAPE IT   Product Pickup

friction-resistance and high oxidation
temperature qualities.
The AE-VTSS is designed to support a wide
range of milling operations including plunging
in stainless steel, cast iron, carbon steel, alloysteel and hardened steel (up to 40 HRC).

AE-CPR4-H
4-flute Long Neck Corner Radius Carbide End Mill for High-hardness Steels

The AE-CPR4-H 4-flute long neck corner radiuscarbide end mill is engineered to achieve
high-efficiency milling in high-hardness steels.
Its new gash specification with a spiral shapeforming from the center to the corner radius
improves chip evacuation and prevents chips
from getting caught. Chattering is minimizedby the AE-CPR4-H’s unequal spacing teeth
geometry, enabling highly efficient machining
even in deep milling of L/D = 14.

With the addition of OSG’s DUROREY coating
and smooth surface treatment, surface
accuracy is further improved. The AE-CPR4-H
is available from diameter 0.2 mm up to 4 mmwith a total of 176 items.

PXSH
Exchangeable Head End Mill for High-hardness Steels

The PXSH is a multi-flute square typeexchangeable head end mill. It is a part of
the PXM exchangeable head end mill series
designed for large-diameter applications.
The PXM series offers significant time savings
versus solid tools as only the exchangeable
head would require replacement. It also
provides greater productivity versus indexable
tools as the exchangeable head can beselected based on the number of flutes.
The PXSH is available in 6-flute and 8-flute
configurations. The PXSH features unequal
spacing teeth geometry to minimize
chattering. With optimal cuttingedge specifications, high efficiency and stable
milling performance can be realized inhigh-hardness steels. In addition, the
PXSH is able to achieve long tool life underaggressive cutting conditions due to the
DUROREY coating’s excellent toughness,high heat resistance and abrasion resistancecharacteristics.

SHAPE IT   Product Pickup 22

OSG Participates at INTERMOLD 2022

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1. OSG staff gather for a group photograph before the start of INTERMOLD 2022 at the INTEX Osaka in Japan.
2. At INTERMOLD Osaka 2022, OSG exhibited its latest tooling innovations, including the AE-H series for high-hardness steel applications.

INTERMOLD is a leading international trade fair thatshowcases state-of-the-art moldmaking technology,
tooling, design and application development.
The 33rd INTERMOLD took place from Wednesday,
April 20 to Saturday, April 23, 2022 at the INTEX Osakain Japan. According to the INTERMOLD Development
Association, approximately 23,875 visitors participated atthe 4-day event.

At INTERMOLD Osaka 2022, OSG exhibited its latest
tooling innovations and hosted a seminar along with
its partner Roku-Roku Sangyo on the topic of direct anddeep rib milling of high-hardness steel material. Key
highlights include the recently released AE-CPR4-H longneck corner radius carbide end mill for high-hardness
steel; as well as the AE-VTSS anti-vibration carbide end
mill that is compatible with sliding head lathes.

Taiho Tool Opens New Office in Taipei
Taiho Tool Mfg. Co., Ltd. (Taiho), OSG Corporation’s subsidiary in Taiwan, has
opened a new office in Taipei on April 13, 2022. Located on the 18th floorof the Chicony Building in Sanchong District, New Taipei City, Taiho’s new
260-square-meter office includes a warehouse to accommodate toolingneeds in the nearby region. Situated approximately 15 minutes away fromthe Taipei Station by car, the 39-story, 181.6-meter skyscraper featuresconference rooms and a selection of dining options, making it a convenient
location for hosting seminars and other company events.

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The Chicony Building in Sanchong
District, New Taipei City, Taiwan.

23 SHAPE IT   OSG News

1. View of the surrounding region from the 18th floor.
2. Reception desk at the Taipei office.

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About Taiho Tool Mfg. Co., Ltd.
Headquartered in Kaohsiung, Taiwan, Taiho Tool Mfg. Co., Ltd. wasestablished in 1969 and is the second overseas subsidiary of OSG
Corporation. Taiho today employs more than 330 staff and has
transformed from a traditional SKS tap factory into a major
high-quality cutting tool manufacturer with production sites, stock
centers and sales offices located throughout Taiwan and mainland
China. Taiho’s key products include taps, nut taps, rolling dies, drills,
end mills and gauges.

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3. Taiho’s new
260-square-meter office.
4. The warehouse of
Taiho’s Taipei office.
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OSG Hosts Benchmark and Networking Event toPromote Competitiveness in Tool and Die Industry
OSG GmbH hosted a benchmark andnetworking event with partner Marktspiegel
Werkzeugbau, a market research firm, toevaluate the tool and die industry with neutral
data at the OSG Academy in Göppingen,Germany on July 7, 2022. More than 60
representatives, primarily decision-makers
from the tool and die industry and suppliers,
participated at the event to cooperatively
benchmark for the first time in this fashion.
Marktspiegel Werkzeugbau evaluates
German tool and die makers as well as series
production manufacturers anonymously
according to their competitiveness, thus
enabling the assessment of positioning
in direct comparison to the industry
environment. The focus of the event was not
only on insights into data and facts, but also
on current market development and trends.
“Becoming better with industry knowledge”
was the motto that ran through the entire
event.

A group photo from the benchmark and networking event with partnerMarktspiegel Werkzeugbau, a market research firm.

Innovations for the Tool and Die Industry
OSG maintains absolute control over every aspect of its manufacturing capabilities. OSG products are produced
in-house – from the production of tool material, creation of tool geometry, to the development of its own
proprietary coatings – the three vital elements in the manufacturing of superior cutting tools. OSG’s expertise in
the tool and die industry is demonstrated by the AE-H series, the company’s latest milling innovation designed
for hardened steel applications. The AE-H end mills are available in a wide range of configurations with stablemachining capability at large cutting depths and long tool life. OSG’s original DUROREY coating with SiC structure
provides superior heat resistance, wear resistance and high surface quality optimized for hardened steel milling.
Through a tour of the production facility, it became clear to visitors in all facets that OSG products are manufactured
in exclusive quality. In addition to tooling solutions, OSG also offers comprehensive services such as machining
strategies for standard products as well as optimization of machining routines at the client’s facility.
SHAPE IT   OSG News 24

OSG Around the World
Employee Interview with

Yoshiyuki Saito
Tell us about your work and experience at OSG.
I studied business management and marketingin college in Japan and the United States. After
graduation, I was recruited by NAS Precision, one
of OSG’s group companies in Illinois, which later
merged into OSG USA. I held multiple roles during
my 14-year tenure in America, where I served as
sales engineer, sales manager, and vice president
at NAS Precision; I was also sales manager at OSG
Sterling Die (a group company that specializes incold forming products and was later merged into
OSG USA); and sales manager at OSG USA. In 2015,
I was transferred to OSG Corporation in Japan andserved as a sales representative at the Nagoya sales
office in the central sales division. Two years later, I
was appointed as the general manager of sales andcustomer service at OSG Thai.

ProfileLocation: Thailand
Position: General Manager of Sales and Customer Service at OSG Thai
Joined OSG: 2001
Motto: “Nothing will happen until action is taken.”Tell us about your daily routine.
My daily routine involves developing new ideas, systems,
and workflow to enhance sales volume. I am also in charge ofmanaging sales and booking, as well as OSG Thai stock items
based on sales record in Thailand.
What is most challenging about your work?
Every country is unique. It is always a challenge to fuse with adifferent culture while attempting to add my own philosophy inthe workplace. People in Thailand respect seniors and are great
listeners. However, they can also be very conservative. It is crucial
to first learn and understand the way of business in Thailand
before applying changes even for the purpose of achieving
higher goals. A longer period of time is required to implementchange in Thailand than what I have experienced in Japan andthe United States.

25 SHAPE IT   Meet OSG

Center, Saito poses with OSG Thai’s sales team for a photograph.

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1. Saito poses for a photograph at the Wat Suthat Thepwararam Ratchaworahawihan in Bangkok, Thailand.
2. Saito poses for a photograph during sunrise at the Red Lotus Lake in Udon Thani, Thailand.
3. Far right, Saito poses for a group photo with OSG Thai employees and the owner and staff of BT&T, a local distributor in Thailand.
4. Wat Rong Khun, better known as the “White Temple,” is one of the most recognizable temples in Chiang Rai Provine, Thailand.
5. The five statues of Budda at Wat Pha Sorn Kaew located in Phetchabun of north-central Thailand.
6. Right, Saito snorkeling with his wife in Ko Raet, Chonburi, Thailand. On his day off, Saito enjoys snorkeling in the oceans.

OSG Thai special step drills.

What is unique about OSG Thai?
We have everything in Thailand because of our multicultural market. There
are many Japanese transplants as well as local Thai companies, Chinese-Thaicompanies and European companies. Thus, not only do we import and sell OSG
Japan products, we also manufacture carbide cutting tools and die products
domestically in Thailand, and provide coating services. Our stock center has
more than 15,000 items and offers stable delivery service for not only OSG Japan
standard items, but also OSG Asia catalog items to fulfill local manufacturingneeds.

What is your favorite OSG tool?
OSG Thai’s special drills are my favorite tools. When I worked as a sales engineer in my first job, I used to design
custom tools based on the client’s drawing. I find it rewarding to be involved in the product development process,with the finished product made in front of my own eyes.
How do you spend time on your day off?
I enjoy traveling to places I have never been to before. In Thailand, there are many beautiful natural sights andhistorical buildings. One of the best places I would like to introduce is Chiang Rai in the northmost province ofThailand. It is filled with beautiful mountain sceneries, incredible temples, and great local Thai food. I also enjoy
snorkeling in the oceans, and Thailand is a fantastic destination for these outdoor activities.

SHAPE IT   Meet OSG 26