OSG Global Tooling Magazine

Reaching
New Heights
Strategic acquisitions to enhance OSG support network
for global aerospace manufacturing

WINTER 2019

Customer Report

Lifting Productivity
TRS 3-flute coolant-through carbide drillslashes machining time in bulldozer
track frame production

Technical Insight

SynchroMaster
Tap Holder

Meet OSG

Employee Interview
in Singapore

Rising to the Next StageA Message from the President
In 2018, OSG recorded the highest net sales in its
history. I would like to express my sincere gratitude
to the support of our customers, business partners
and employees for making this achievement possible.
OSG will continue to focus on customer demand inaccordance with changes in times, and strive to live up
to our reputation as your number one reliable partner.
Although the global economic health has beenvery robust this past term, we are also faced with
rapid changes and uncertainties. Digitalization andelectrification are spreading across all industries. The
automotive industry is no exception. Electric vehicles(EVs) have become the gateway to the future of mobility.
I suspect that someday in the future, battery-poweredmodels will take reins from the combustion engine as
the king of the road. Cars will simply become a giant
sensor and a part of the big data phenomenal that drives
the global economy. OSG is positioned to respond to thesudden surge of technological transformation and will
endeavor to continue to expand its business domains.
As geopolitical tensions intensify with a potential decline
in global trade, OSG is prepared to further enhance its
production system to provide uninterrupted products
and services to its patrons. In the next three to four years,
OSG will invest approximately 50 billion yen or more
to revamp its global production system, ensuring that
it is optimal, flexible and highly competitive. Working
in unison with our global network to provide the best
service possible, I am confident that OSG will rise throughuncertainties and preserver into the next stage in time.

Norio Ishikawa
President & CEO of OSG Corporation

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SHAPE IT   ﻿CONTENTS Feature
SHAPE IT WINTER 2019

3 Reaching New Heights

Technical Insight
11 SynchroMaster Tap Holder

Customer Report
15 Lifting Productivity
19 High-Feed, High Accuracy & Tight Tolerances Milling
21 One Tap Does It All

Product Pickup
25 ADO-TRS 3-Flute Carbide Drill, ADFO Flat Drill
26 AE-VML Anti-Vibration Carbide End Mill, ADO 40xD & 50xD Coolant-Through Carbide Drills

OSG News
27 2019 Exhibition Schedule

Meet OSG
29 Employee Interview in Singapore

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: January 2019
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) 533-82-3288 Fax: (81) 533-82-1132 www.osg.co.jp

SHAPE IT   ﻿

2

Reaching New Heights
Strategic acquisitions to enhance OSG support network
for global aerospace manufacturing
Max Suzuki
OSG Corporation

3

SHAPE IT   Feature

The aerospace industry is expected to witness significate
growth in the coming years with increasing air travelin China, the Middle East and other emerging nations.
Globally, the demand for new technologically advanced
fuel-efficient aircrafts continues to rise. Manufacturers
are always in seek of improved materials and processing
methods to enhance parts in less time, build complex
features with ease while maintaining overall cost
efficiency.
The demand for advanced aircrafts also accelerated theconsumption of superalloys and composite materials.
Heat-resistant superalloys, such as nickel alloys, provide
strength and structural reliability at high temperatures,
which is required in advanced jet engines. In addition
to superalloys, a large percentage of new aircrafts
components include composite materials due totheir superior strength and substantially lightweightcharacteristics.
As failure at 35,000 feet above ground has major
consequences, the aerospace industry has extremely
low tolerance of risk. Aviation parts and components arehighly regulated with strict requirements. Certification
is a major barrier to entry into the aerospace sector. OSG
has been promoted to the Advanced Manufacturing
Research Centre (AMRC) Tier 1 tool supplier since June
2015. As AMRC is the world’s most advanced aerospaceresearch facility, this achievement is a recognition of
OSG’s advanced technology and ability to work on awide range of projects with utmost quality control.
For many years, OSG has supplied cutting tools forthe processing of aircraft parts around the world.
OSG has built a high reputation for its capability toeffectively process difficult-to-machine materials suchas superalloys and composites. As technology continues
to evolve, OSG is also constantly researching anddeveloping new cutting tools solutions dedicated tothe aerospace industry. Acquiring and responding tocustomer feedback is one of the most critical processes
in product development. To better serve end users
and to obtain accurate feedback, OSG has strategicallyacquired three aerospace related manufacturers inFrance and the United States in the past couple of years– SMOC Industries, AMAMCO Tool and Desgranges
Holding S.A.S.

SHAPE IT   Feature

4

September 2017
SMOC Industries in France
OSG became the major shareholder of SMOC Industries
by taking 55 percent of its shares in September 2017.
Founded in 1946, SMOC is a French manufacturer basedin Tullins, a small city in the heart of the Alpes. In the earlydays of SMOC, the company specialized in the productionof special cutting tools and form tools for milling andturning machines. In 1969, SMOC began manufacturing
broaches. In 1975, SMOC began the development of
Christmas type broaches for Airbus engines.
Today, SMOC is a leading manufacturer in Europe
for aircraft engine cutting tools. SMOC relies on its
creativity, innovation and research and development
team to ensure continuous progress. In spirit ofinnovation and research, SMOC has been involved
for many years in several aircraft research programs,
including the LEAP engine, which was developed by
Safran Aircraft Engines and GE.

1

5

As of 2017, SMOC employs over 100 staff and has
recently opened a new 1,600-square-meter facility
dedicated to aeronautic and tool management inaddition to its existing 3,500-square-meter production
capacity in three buildings in Tullins. With 40 CNC
machines working in three shifts, SMOC is able tomanufacture any kind of round or flat broach. In
addition to new tools, SMOC also offers re-sharpening
services, tool repair, management of tools, and technicalassistance on site.
Looking ahead to 2019, SMOC is scheduled to open a
new re-sharpening center in China and strives to expand
its presence in the United States. SMOC will look to relyon the OSG global network to continue to strengthen its
international expansion.

2

SHAPE IT   Feature

3

1. An image of SMOC Industries’ Christmas tree broaches, which are used to manufacture slots on turbine disc for helicopter engines, aircraft
engines and gas turbines.
2. Utilizing some of the latest manufacturing equipment, SMOC maintains high quality control throughout its production process.
3. Profile grinding of the Christmas tree broaches at SMOC’s production facility in Tullins, France.

SHAPE IT   Feature

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April 2016
AMAMCO Tool in the United States
AMAMCO Tool, located in Duncan, South Carolina,
was founded in 1972. As of April 2016, the company
operates as a subsidiary of OSG USA, Inc. AMAMCO Toolis a custom, cutting tool manufacturer that designs andproduces application-specific cutting tools primarily forthe aerospace and composite industries. Core products
include drills for hand, CNC and advanced drilling units(ADU). The company also manufactures high quality
diamond coated routers and drills currently used by all
major and Tier 1 aerospace manufactures in the UnitedStates and abroad.
With a passion for quality and service forged in its
foundation, AMAMCO currently has a work force
approaching 100 with an average tenure of over 11
years. As AMAMCO continues to grow, the company
plans to further expand its production floor space inthe next 12 to 18 months in addition to its existing
35,000-square-feet manufacturing facility.

AMAMCO helped develop innovations on the Boeing
787 Dreamliner development project, a success thathas helped to carryover to supply contracts on the777, 737 and other aircraft production lines. Due to its
success at Lockheed, Boeing and other manufacturers,
and while competing against much larger, international
companies, AMAMCO consistently achieved excellencein providing superior tools and technical services.
Winning many critical contracts, the company often
achieved “single source” supplier status for its manycustom prints and designs, acquiring exclusive
production relationships.
AMAMCO is proud to be a part of the OSG family andlooks forward to a long and productive future, providing
innovative solutions to the aerospace and wide varietyof the many other industries OSG and AMAMCO serve.

1

1. AMAMCO Tool in Duncan, South Carolina, USA. AMAMCO is well known for manufacturing combination drills, countersinks, counter bore
and high-quality reamers.

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SHAPE IT   Feature23

2. AMAMCO’s flute grinding department. AMAMCO
Tool was built to offer alternatives to the morecommonly mass-produced, ‘off-the-shelf’ cutting tools,
while contributing innovative custom development
and prototype solutions.
3. AMAMCO compression router with cuttingedge geometry design, using two opposing flutes
configured to sandwich composite layers together,that eliminated delamination. A diamond coating is
also applied to the cutting surface using, at the time, a
recently developed chemical vapor deposition (CVD)
process.
4. F-35 production line in Texas, USA. With capabilities
to eliminate delamination in the routing of advanced
carbon fiber (CFRP) composite wing skin material whileachieving significantly longer tool life versus othercutting tool providers, several AMAMCO diamondcoated tools are currently used by Lockheed in drilling
applications on the F-35. Photo courtesy of Lockheed.

4

SHAPE IT   Feature

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September 2015
Desgranges Holding S.A.S. in France
Established in 1946, Desgranges is a French
manufacturer of standard and special cutting tools,
and supplies to major French contractors in civil
and military aviation, automotive and high-tech
related sectors. Its primary efforts are focused on
the machining of hard materials, the assembly andmachining of composite materials and stacks, andservices associated with the cutting tool life cycle.
Located in Andrézieux Bouthéon Cedex, France,
Desgranges currently employs 81 staff and has
a 3,000-square-meter production capacity. From
Concorde to the A350, Desgranges has always beenheavily involved in the manufacture of cutting
tools for the aeronautical industry. This extensive
experience has given rise to the creation of Nexam
in 2005, a brand of tools specifically for assembling
airframes. In 2008, Desgranges Cutting Tools becamea strategic supplier for Airbus. In September 2015,
Desgranges Cutting Tools sold 100 percent of
its shares to OSG. The acquisition allows OSG tofurther expand its operations in Europe while theDesgranges group is supplied with valuable means
to accelerate product development.

12

1. Desgranges Cutting Tools in Andrézieux-Bouthéon, France.
Desgranges is a French manufacturer of standard and customized
cutting tools for sectors including civil and military aviation,
automotive and high-tech industry.
2. Desgranges operator on a CNC machining center.

9

SHAPE IT   FeatureTo enhance growth and to provide the best possible
aerospace solutions for manufacturers, OSG
actively participates in strategic collaborations andpartnerships. Each of OSG’s subsidiaries are equippedwith unique strengths and offer their own special
products. With these new innovative partners, OSG
will strive to continue to aid manufacturers shape thefuture flight path of aerospace technology.

SHAPE IT   Feature 10

SynchroMaster
Tap Holder
Next generation synchronized tap holder designed toturbocharge tapping performance
Takayuki Nakajima
OSG Corporation Applications Engineer(Tap Development Division)

Machining troubles associated with tap processing
are far more frequent in comparison to other rotating
tools, such as drills and end mills. Manufacturers often
struggle with threading applications because there
are few effective solutions. For example, what kind of
measurements would you take to achieve the following?
• Prevent sudden breakage of taps
• Stabilize tap life
• Improve thread quality• Stabilize short chamfer taps’ performance
All of the above are difficult to achieve. When a tapping
problem arises, most operators would troubleshoot bylowering the cutting speed, which would in turn reduce
productivity.
To help manufacturers who use machining centerswith synchronous spindles overcome these common
tapping obstacles, OSG Corporation has recently
introduced a new generation synchronized tap holder– the SynchroMaster – engineered to turbocharge
performance by dampening excessive forces in rigid
tapping environment.
The SynchroMaster tap holder is designed to turbocharge
tapping performance on CNC machines with synchronous
spindles by compensating for synchronization errors during thethreading process.

11 SHAPE IT   Technical InsightWhy Tap Processing is Difficult
One of the causes is that the feed per revolution is fixed.
The cutting of internal threads is performed by thechamfer section of a cut tap. In principle, the full thread
portion of a cut tap does not perform any cutting, but
merely follows the path cut by the chamfer. As the tap
rotates, each cutting edge of the chamfer gradually
increases the depth of cut along the lead, which forms
the thread ridges to guide the position of the tap
thereafter. Figure 1 illustrates the tapping process in thecase of a 4-flute cut tap.

Figure 1. Cutting process of tap (4-flute)
Chamfer

Rigid tapping, also known as synchronous feed tapping,is one of the most common tapping methods used onmodern machining centers. If the machine’s spindle
rotation and feed are synchronized to match a specificthread pitch as the tap is driven in and out of a hole, theshape of the pitch would be correctly formed. When
there is a feeding error (leading or delaying), a size
reduction (pitch dislocation or enlargement) would
occur, which affects the precision of threads. Figure
2 illustrates a scenario where the tap feeding error(leading) occurred due to excessive cutting force, whichcauses size reduction of the internal threads.
Figure 2. Size reduction due to cutting by leading

Full thread portion

Internal thread

Cutting edges

1st

5th

9th .........
Size reduction of internal threads

Cutting area of final
chamfer cutting edge

Internal thread

Cutting area by 3rd cutting edge
Cutting area by 2nd cutting edge
Cutting area by 1st cutting edge

Theoretically, a solid type tap holder without any
tension-compression is appropriate for machining
centers with synchronous spindles. However, there
will always be small discrepancies between thesynchronization and the actual movement (feed) of
the specific tap being used. As the machine ages, thediscrepancy between the spindle speed and feed andthe tap’s movement can become more significant. Witha solid holder where no movable value is permitted, any
deviation occurred would increase the thrust load on
the tap, which would greatly reduce tool life and thread
quality due to the extra axial forces being exacted.

Tapping direction

Fortunately, with the right combination of machining
center and tap holder as illustrated in figure 3, feeding
error can be prevented.

Figure 3. Combination of machining center and tap holder
Machining Center

Tap Holder

Movable Value

Without synchronous spindle

TapperLarge: 5-7mm

Solid holder

0

SynchroMaster

Small: 1mm +/-With synchronous spindle

SHAPE IT   Technical Insight 12

High thrust force andan increase in cuttingpressure are caused by thediscrepancies between
calculated feed and actual
movement of the tap. The
SynchroMaster tap holder’sunique micro float unit
eliminates the extra axial
forces on the tap to enable
long tool life, stable tapping
performance and precision
thread quality.

Features & Benefits of SynchroMaster
The SynchroMaster is a tap holder constructed to allow a slight amount of axial
movement to compensate for axial deviations that are unavoidable in rigid tapping. Its
micro tension-compression float eliminates the extra axial forces on the tap, leading tolonger tool life, consistent tapping depth and improved thread quality. As illustrated
in figure 4, the uniquely integrated float unit absorbs the loads in the thrust direction,
significantly reduces thrust forces occur during reverse rotation.
Figure 4. Comparison of thrust force during machining
Normal rotation

Reverse rotation

100

Thrust ( N)

0
-100
-200
Work Material : S45C

-300
-400
-500

Tool : A-SFT M4×0.7

In solid holder, the thrust load greatly
increases as the tool reverses out of thehole due to synchronization error

Cutting Speed : 25m/min

Time (s)SynchroMaster

13 SHAPE IT   Technical Insight

Solid Type Holder

Cutting Data
Figure 5 illustrates a tool life comparison of a shortchamfer tap when used in combination with the
SynchroMaster tap holder and a solid type holder.
The cutting tool used for the test was a M4 x 0.7 1P
short chamfer spiral tap. The shorter the chamfer, thecut made per cutting edge increases. For this reason,
applications with short chamfer taps can easily become
unstable. Tapping in S45C, the M4 x 0.7 1P shortchamfer spiral tap with solid type holder averaged
approximately 200 holes. When use in combination with
the SynchroMaster tap holder, on the other hand, thrustload was significantly reduced and the short chamfer
tap was able to achieve nearly five times the durability
versus the solid type holder.

Additionally, as illustrated in figure 6, the SynchroMastertap holder is effective not only for cut taps, but also forform taps. Since cutting does not take place with form
taps and the internal thread is processed by using theplastic deformation of the material, the processing load
for form taps is even higher than cut taps. As highlighted
in figure 6, the SynchroMaster tap holder was able todouble the tool life versus solid type holder even forform taps.

Figure 5. Short chamfer spiral tap tool life comparison

Figure 6. Form tap tool life comparison

Tapping Holes

200

SynchroMasterSolid Type Holder

400

Tapping Holes

600

800

1,000

SynchroMaster1,000 Holes
888 Holes
360Holes
231
169

Early wear

5 times

Holes
Work Material: S45C

Tool: A-SFT M4 x 0.7 1P

200

Cutting Speed: 10m/min

For manufacturers who are especially struggling withunstable tool life, poor thread quality, low productivity
and large variations in depth length on rigid tapped

Solid Type Holder

400

600

800

1,000

1,200

1,051 Holes
1,151 Holes
478 Holes

2 times383 Holes
Work Material: SCM440 (30HRC)

Tool: S-XPF M10 x 1.5 2P

Cutting Speed: 15m/min

holes, look to the SynchroMaster tap holder toturbocharge your tapping performance.

SHAPE IT   Technical Insight 14

1 From left to right, Komatsu Operator Waldir dos Santos Tavares, Komatsu Process Engineer Rafael Fernando Braz and OSG Sales Technician

Valdir Lima inspect the TRS 3-flute coolant-through carbide drill in front of a track frame at the Komatsu do Brasil plant in Suzano, São Paulo.

Lifting
Productivity
TRS 3-flute coolant-through carbide drillslashes machining time in bulldozer trackframe production
Valdir Lima, OSG Sulamericana

2

A track frame, which is a side-frame component of the bulldozer, waits forcompletion at Komatsu do Brasil’s production plant in Suzano, São Paulo.

15 SHAPE IT   Customer Report

Harsh, dangerous, stressful, demanding and masculine
are common keywords come to mind when referring to
the heavy industry, which may include construction andmining. Due to these negative perceptions, this sector
often struggles to secure adequate skilled professionals
while facing a backlog of projects. Against the generalstigmas, jobs in heavy industry have a high degree of
autonomy and employ some of the most sophisticatedand powerful machines in their manufacturing process.
Komatsu Limited, a Japanese multinational corporationand one of the world’s largest manufacturers ofconstruction equipment and mining equipment, is a key
player in support of the growth of the heavy industry
worldwide. Founded in 1921, the Komatsu Group today
consists of over 180 companies around the globe. In
1975, Komatsu do Brasil Ltda. was established to serve
as Komatsu’s South American division.
Located in Suzano, São Paulo, the Komatsu do Brasil
plant has approximately 634,000-square-meter of
production floor space and employs 647 staff. At thisstate-of-the-art facility, Komatsu do Brasil is always
looking for new solutions to boost speed, safety andcost efficiency to provide heavy industry businesses
with reliable quality products.

3

A Shin Nippon Koki CNC portal milling machine is used for the production of track frames for Komatsu’s bulldozers.

Bulldozers are some of Komatsu do Brasil’s coreproducts. A bulldozer is a tractor fitted with a dozer
blade used for maneuvering materials such as soil, sandand rubble. Bulldozers are used on a wide range of sites,
including mines, military bases, heavy industry factories
and farms to handle projects that require highly mobile,
powerful and stable earth-moving equipment.
A bulldozer is made up of a number of components,
such as the cab, track, coiled track, frames, blade, engine,
hood, rollers, idlers, and more. The manufacturing ofbulldozers requires a combination of processes, suchas CNC machining, welding and powder coat painting
involving skilled technicians as well as robotic support
with automated assembly line.

Komatsu was seeking processing improvement intheir production of track frame, which is a side-framecomponent of their bulldozer. In terms of production
volume, Komatsu manufactures approximately 1,200
vehicles per year.
Made of cast steel, each track frame has 46 throughholes measured at 14 mm in diameter and 37 mm indepth. The machining center being used to produce
these track frames is the Shin Nippon Koki CNC
portal milling machine. A BT50 tool holder is also
used to secure the tooling. Komatsu was originallyusing a competitor 2-flute double margin coolantthrough carbide drill with a 140-degree point angle
for this application. With the 2-flute drill, Komatsu
was encountering problems such as tool breakage,processing time and performance instability.

The TRS “Mega Muscle” drill isdesigned specifically for drilling atfeed rates 1.5 to 2 times faster than
2-flute drills. The TRS is suitable for any
application that currently uses 2-flute
coolant-fed drills in cast aluminum,
cast iron, carbon steels, alloy steel,die steel, stainless steel and hardened
steel less than 45 HRC.

SHAPE IT   Customer Report 16

Two-flute drills have their limitations when theneed to cut production cost in half while doubling
efficiency arises. Looking to improve production cost
efficiency, Komatsu Process Engineer Rafael Fernando
Braz, who is responsible for the manufacturing of
the track frames, consulted with OSG regarding theapplication, as Komatsu and OSG havea long-time partnership in both
Brazil and in Japan. Upon a detailevaluation of the application,
OSG recommended the 14 mm
diameter TRS “Mega Muscle”
5D 3-flute coolant-throughcarbide drill (EDP# 8663400).

processing of materials with short cutting chips, suchas cast iron and cast aluminum. Because 3-flute drills
have a smaller flute size (chip room) than 2-flute drills,
they are less frequently used in difficult-to-machinematerials like steels. OSG’s TRS is the world’s first 3-flute
drill for steels with patented flute shape that breaks steel
chips into small, manageable pieces for easy evacuation,
enabling ideal performance even in steels. This featureallows for increased feed rates up to 1.5 to 2 times fasterthan 2-flute drills. Further, its 120-degree equal spacing
margin allows vibration-free processing and improved
hole tolerance with less work hardening, which gives
secondary operations such as tapping even more toollife.

Conventional 3-flute drills aremost commonly used in the

The original competitor tool was running at a rotational
speed of 1,800 min-1, feed rate of 455 mm/min, and

4. The TRS “Mega Muscle” drill
is the world’s first 3-flute drill
for steels. Patented geometry
permits stable chip ejection,even with less chip pocket
space inherent in 3-flute drills.
The TRS is able to help Komatsu
reduce machining time by 30
percent and double tool lifein their production of trackframes.

4

5. A pair of track frames
pending for completion at
Komatsu do Brasil’s production
plant in Suzano, São Paulo.

5

17 SHAPE IT   Customer Reportcutting speed of 70 m/min. The processing time per partwas 22 minutes. The TRS, on the other hand, runs at a
rotational speed of 1,900 min-1, feed rate of 950 mm/min
and cutting speed of 85 m/min. The TRS is able to reduce
processing time to 15 minutes and 52 seconds per part,which is equivalent to approximately 30 percent time
reduction. In terms of tool life, the previous toolingchoice required four drills per month. With the TRS,
only two drills are required per month, decreasing toolconsumption by half.

The heavy industry is a key sector that contributes tothe development and growth of the global economy.
As Komatsu has demonstrated, dirty and manual work
is a stereotype of the past. The modern heavy industry
is high-tech, safe, powerful and reliable. As the heavy
industry’s tough materials and large production require
strong tools designed for performance, OSG is ready tosupply superior tooling solutions to help manufacturers
in this important sector continue their journey of
constructing excellence.

“When we needed improved performance, OSG’s TRS
drill demonstrated superior results for our application,”
said Komatsu Process Engineer Rafael Fernando
Braz. “The TRS 3-flute drill helped us solve a criticalapplication very successfully, and we intend to expand
this solution to other applications.”“Our partnership with OSG has always been a positive
experience,” said Braz. “In addition to providing
satisfactory tooling solutions, OSG’s staff always supply
us with the latest metal cutting knowledge so that
we can fully leverage the cutting tools as well as ourequipment to reach optimum cost efficiency.”

67

6. A close-up of a completed
track frame on a bulldozer. The
manufacturing of bulldozers
requires a combinationof processes, such as CNC
machining, welding andpowder coat painting involving
skilled technicians as well as
robotic support with automatedassembly line.
7. A fleet of completed
bulldozers lining up at the
Komatsu do Brasil’s production
plant in Suzano, São Paulo.
A bulldozer is a tractor fittedwith a dozer blade used for
maneuvering materials suchas soil, sand and rubble. A
bulldozer is made up of anumber of components, suchas the cab, track, coiled track,frames, blade, engine, hood,rollers, idlers, and more.

SHAPE IT   Customer Report 18

High-Feed,
High Accuracy &Tight Tolerances Milling
WXS-LN-EBD rib processing ball nose end mill demonstrates long tool life and superior
accuracy in high-feed processing of metal rollers at 54 HRC
Magnus Hoyer, OSG Germany

The WXS-LN-EBD is a 2-flute, long-neck ball nose carbide end mill designed for high-feed milling of hardened steels up to 65 HRC andstainless steels.

A manufacturing process that involves the embossingof sheet metal stamping rollers in 1.2379 tool steel at alength of 80 mm. At first glance, the production of thiscomponent seems neither demanding nor difficult. The
challenge, however, lies in the detail, which involves
maintaining a tolerance of 0.01 mm and continuousmachining of up to 24 hours. With the small diameterembossing, the cavities in the rollers are positioned
tightly, which prevents the use of high-feed-rate as
the milling machine does not have adequate room toaccelerate or decelerate. As a result, the cutting tool forthe job has to quickly grind through the short traverse
paths with great precision. With the rollers being madeout of high hardened materials at 54 HRC, an end millwith a sharp cutting edge would be the typical toolingchoice. At least that was the experience for PräWebaEngraving and HSC Technology GmbH.
Established in 1996, PräWeba is a group of specialists
for CNC production located in Bad Lauterberg,
southern Harz, Germany. Lead by Managing Director
Rolf Stilzebach, who has years of experience in the

19 SHAPE IT   Customer Reportprogramming of part processing, PräWeba’s coreservices include engraving, tool making, forming and
CAD services. PräWeba works with a wide variety ofrequirements, surfaces and materials, such as plastic,
Plexiglas, brass, aluminum, stainless steel, and othermetals up to a hardness of 65 HRC.
For more than two decades, PräWeba has supplied
precision products for various renowned clients around1

Because the cavities in the metal stamping rollers are so tightly
packed, PräWEBA sets its cutting parameters to approximately 90
percent value of OSG’s recommendation for the WXS-LN-EBD.

the world for their industrial applications. PräWeba
prides itself in its quality of work. The company places
great emphasis on dimensional and detail accuracy.
In metal manufacturing, even minimal inaccuracies inseemingly unimportant parts may add up in subsequent
processes in such a way that the overall result is
unacceptable. To guarantee absolute precision, PräWeba
always manufactures products using modern CNC
milling machines, high quality clamping systems andoptimum cutting tools.
In the case of PräWeba’s metal roller production, which
involves the machining of tightly packed cavities, thetolerances for the final product are in the micrometer
range, where the tolerance of the embossing tool
must lie within +/- 0.01 mm utilizing a cutter diameter
between 0.4 and 0.8 mm.
As tooling cost is factored into the cost of the overall
production, which would be passed on to the client,
PräWEBA is always particular with their tooling choice.
PräWEBA welcomes new tooling solutions as long as
significant improvements in cost efficiency can beachieved. The tooling that PräWEBA initially employed
was fair. However, when compared with the WXS-LNEBD, OSG is the obvious winner in both processing time
and tool life.
The WXS-LN-EBD is a 2-flute, long-neck ball nose carbide
end mill designed for high-feed milling of hardened
steels up to 65 HRC and stainless steels. Equipped with
OSG’s original WXS coating for superior heat and wear
resistant, this rib processing end mill series is able toachieve optimal performance with high precision andefficiency under aggressive machining conditions.
PräWEBA was running their previous milling cutter at a
speed of 13,000 rpm. In contrast, OSG’s WXS-LN-EBD ballnose end mill is capable of running at a speed of 18,000
rpm under identical cutting environment. Furthermore,
every embossing roller would cause a great deal of wearon the cutting tool due to the metal’s high hardness at
54 HRC. PräWEBA’s previous tooling choice required 16
to 20 end mills per roller. With OSG’s WXS-LN-EBD, only
six end mills are required per roller.
“We have tested, calculated and weighed up ouralternatives,” said PräWEBA Managing Director Rolf
Stilzebach. “The conclusion is that OSG’s WXS-LN-EBD
is capable of running at higher feed rates and gives us
approximately 20 to 30 percent longer tool life, saving us
considerable tooling costs.”
As the WXS-LN-EBD is designed for highly efficient
milling in applications involving hard metals, intricate
details and smooth finishes, PräWEBA is using it for
both semi-roughing and finishing processes to take fulladvantage of the tool’s dual capabilities.
Machining centers today are capable of following
precise, complex tool paths at high feed rates. With theright tooling choice, even intricate parts that require
high accuracy with tight tolerances can be processed athigh feed rate to maximize cost efficiency.

2

3

After switching to OSG’s WXS-LN-EBD rib processing ball nose end
mill, PräWEBA is able to increase tool life by an estimate of 125
percent in their production of metal stamping rollers.

From left to right, PräWEBA Production Manager Sascha
Wedemeyer, PräWEBA Managing Director Rolf Stilzebach and OSG
Sales and Technical Specialist Nico Henze.

SHAPE IT   Customer Report 20

One Tap Does It All
Multi-purpose A-Tap series helps
automotive manufacturer simplify
tool management withenhanced efficiency andtool life
Jiang Encheng, OSG Shanghai

If you ask me to compare work to running,
I think our daily work is a 100-meter
dash, providing cutting tool solutions is
a 1500-meter race, and recommending
appropriate new products is a 4x400-meter
relay. What kind of a race would satisfying
customers’ needs be?
In my opinion, it would be an endlessmarathon.

During the lean production meeting about a year ago,
we visited the northern city, which is famously known
as the Detroit of China for its automotive industry. The
entire 1,200 km journey is equivalent to the distancefrom London to Budapest. However, in this remote
city, there are more than 300 automotive factories,
and our customer is one of the biggest manufacturers
in China with over 130,000 employees. During thisjourney, we visited one of their production facilities withapproximately 600,000-square-meter of production
floor space and over 1,500 staff.
In the automotive industry, no matter how stableproduction is, every factory has its own requirements
for cost control and processing efficiency, which also
applies to the cutting tools they employ.

The A-Tap is known for its superior chip evacuation capability. It isan all-purpose tap series developed to accommodate a wide variety
of materials and machining environments, helping manufacturers
simplify tool management.

21 SHAPE IT   Customer ReportAn automobile is consisted of many different parts
made of various materials, such as aluminum, carbon
steel, alloy steel, cast iron, stainless steel, and more. Eachmaterial has different characteristics. For example, toeffectively machine aluminum alloy, the cutting tool
needs to be sharp with capability to withstand welding.
Cutting tools used for machining cast iron must be rigid
and has good wear resistance. For stainless steel, tools
should have a good balance between wear resistanceand toughness. Having a cutting tool specificallydesigned for a designated material is ideal. However,when it comes to tool management, the idea of material
specific tooling can become inconvenient. When amanufacturer works with a new product with a different
material, cutting tools would have to be repurchased,
and this procedure is especially common in threading
processes.
During the lean production meeting, we introduced
OSG’s A-Tap series to the customer for consolidate
tooling management, as it is designed to accommodatea wide range of materials. The customer, whose namecannot be disclosed due to confidentiality reasons, did
not have any previous experience with multi-purpose
taps and was highly suspicious of the concept.

OSG’s A-Tap is an all-purpose tap series designed
to simplify tool management and to excel in a wide
variety of materials and applications. Achieving
trouble-free chip evacuation with a spiral tap in blindholes is particularly challenging and is a main causeof headaches for many manufacturers. To resolve thisproblem and to improve the ejection of chips, OSG’s
A-Tap A-SFT has adopted a variable helix flute design,
which encourages stable chip evacuation and reduces
cutting forces. The helix angle changes from thechamfer, where chips are formed, to the flutes, wherechips are evacuated. This unique geometry enables

SHAPE IT   Customer Report 22

greater chip control that can help produce tightly
compacted chips for easy ejection from the hole.

machine. We ran the trial twice with a new tool for eachmaterial to measure result.

To accommodate a wide range of cutting conditions,powdered metal HSS and OSG’s patented V coating
have been employed in this series to achieve excellent
wear resistance. In addition, to enable high speed
machining, the A-Tap series incorporates a uniquecutting edge design that emphasizes sharpness. Not
only does the A-Tap series perform well in general steel,it also excels in difficult to machine materials such as
stainless steel and mild steel. The A-Tap is compatible
with various types of machining equipment – frommanual machines to the latest advanced machining
centers.

At the end of the trial, the average tool life was 1,400
holes in S50C at a cutting speed of 15 m/min, 4,000
holes in ADC at a cutting speed of 20 m/min, and 1,000
holes in SUS304 at a cutting speed of 10 m/min. What’smore impressive is that all of the taps could continue tobe used due to minimal wear. Because of the excellent
versatility, performance and tool life, the number oftaps required for this customer’s production could be
reduced by 15 percent.

After sharing a great deal of cutting data with successful
results, the customer was willing to put the A-Tap A-SFT
spiral tap to the test.
During the cutting tool trial, we used six pieces of A-SFT(M8X1.25) to process three different materials – carbon
steel, aluminum alloy and stainless steel, on the same

After this initial success, this client consulted with us
on a different process – the threading of an aluminumengine cylinder block with an annual production
volume of approximately 250,000 pieces. A M20x1.5 tap
is used to thread a bottom-through cross-hole using a
local Chinese brand vertical machining center.
The client’s previous tooling choice had chip evacuation
problems, where the chips would have to be removed
manually every time, which affects the stability andefficiency of the production.

1. Chip evacuation problem
was a headache for theclient in their production ofaluminum engine cylinder
block. Cutting chips had
to be removed manually
every time, which affects thestability and efficiency of the
production.
2. A clean thread produced
by a custom A-SFT with extra
oil holes on the side.

1

23 SHAPE IT   Customer Report2After a throughout evaluation of the application, we
concluded that the A-Tap A-SFT is also a great fit for theprocess. In order to resolve the problem completely, we
recommended adding oil holes on the side of the A-SFT,
which OSG offers as a custom item. With the aid of theextra cutting lubricate, the cutting chips are able to beejected from the hole smoothly during the threading
process. Moreover, with the previous tooling choice,in order to create stable chip shape, the cutting speed
had to be maintained at 35 m/min. If the cutting speed
exceeds 35 m/min, the volume of the spiral chip would
be enlarged, making it more difficult to be evacuated.
With the A-SFT, on the other hand, the cutting speed isable to be increased from 35 m/min to 50 m/min, which
increases the processing efficiency by 42.8 percent.

With an increased processing efficiency and thecapability of being able to average 20,000 holes in tool
life, this client could not be more satisfied and has since
implemented more of the A-SFT in their productionlines.
The demand of manufacturers is constantly evolving
and the need for improvement is never-ending, just likean endless marathon. Although there is no end, we must
continue our journey of continuous development tohelp manufacturers stay ahead of their race.

Scan for details

SHAPE IT   Customer Report 24

ADO-TRS “Triple Revolution”
3-Flute Coolant-Through Carbide Drill Series

The ADO-TRS “Triple Revolution” is OSG’slatest drilling innovation for ultra machining
efficiency in a wide range of materials. Its
unique R gash geometry enables high thrust
resistance and exceptional chip control,
which are common challenges of 3-flute
drills. With its low cutting resistancecapability comparable to 2-flute drills,

the ADO-TRS is able to create short andcompact chips stably. Furthermore, its wide
chip pocket configuration allows trouble-freechip evacuation even at high speeds andfeeds. With the addition of OSG’s original EgiAS
coating, superior wear resistance and long tool
life can be achieved.

ADFO
New Coolant-Through Style Added to ADF Flat Drill Series

The ADF multi-purpose flat drill series
for inclined surfaces and counterboring
applications has been expanded with thecoolant-through ADFO suitable for stainlesssteel applications.
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 precisionand minimizes the shifting of the hole position.

25 SHAPE IT   Product Pickup

Its sharp cutting edge results in low cutting
force to minimize burrs even in thin plates.
With wide chip room geometry, trouble-freechip evacuation can be achieved. Furthermore,with the addition of OSG’s new proprietary
EgiAs coating, tool life can be prolonged withexcellent heat and wear resistance.
The ADF is engineered for a wide varietyof drilling applications including inclined
surfaces, curved surfaces, counterboring,eccentric holes, thin plates, etc.

AE-VML
New Long Flute Style Added to Anti-Vibration Carbide End Mill AE-VMS Series

The highly anticipated long flute AE-VML for
high-speed side milling has been added to
OSG’s AE-VMS anti-vibration carbide end milloffering, a series designed to attain an all newlevel of milling efficiency coupled with superb
finish quality suitable for a variety of milling
applications.
High-speed side milling is made possible by
the AE-VML’s large thick core design. Its uniqueflute form with high tool rigidity and excellent
chip evacuation properties enables stable
milling performance and the suppressionof burrs. With the addition of OSG’s original
DUARISE coating, tool life can be enhanced

by its excellent lubricity, superior frictionresistance and high oxidation temperature
qualities. The DUARISE coating’s multi-layer
construction minimizes thermal cracks,
allowing the AE-VMS series to excel even inwater-soluble oil.
Available in square, radius, stub length, longneck and long flute, the AE-VMS is designed
to accommodate a wide range of milling
operations including slotting, side milling,helical milling, contour milling and ramping
in stainless steel, cast iron, carbon steel, alloysteel and hardened steel (up to 40 HRC).

ADO
40xD and 50xD Sizes Added to ADO Next Generation
High Performance Carbide Drill Series

The ADO series, OSG’s premium line of solid
carbide drills with through coolant, has been
expanded with 40xD and 50xD sizes for highly
efficient deep-hole drilling. The ADO’s unique
R gash geometry enables super low cutting
resistance and exceptional chip control. Its
new flute specification with smoothchip evacuation and high tool rigidity
qualities are engineered for optimum
performance in ultra-deep-holeapplications.

SHAPE IT   Product Pickup 26

Global Events

2019 Exhibition Schedule
01

January
January 24–30

IMTEX

Bangalore, India

02

03

February
February 5–7

Expo
ManufacturaMonterrey, Mexico
February 5–8

Intec

Leipzig, Germany
February 21–23

LMT Lab Day

Chicago, USA
February 26–28

HOUSTEX

Houston, USA

March
March 3–5

Grainger Show

Orlando, USA
March 5–8

Industrie Lyon

Lyon, France
March 12–14

InnoForm

Bydgoszcz, Poland
March 12–16

IDS

Cologne, Germany
March 12–16

INTERMOLD
Korea

Goyang, Korea
March 27–29

CMPI

Chongqing, China

27 SHAPE IT   OSG News

04

April
April 6–8

ISA

Houston, USA
April 15–20

CIMT

Beijing, China
April 16–18

Fastenal
Customer Expo

Aurora, USA
April 17–20

INTERMOLDTokyo, Japan05
May

May 7–11

EXPOMAFESão Paulo, Brazil
May 9–11

CCEME

Zhengzhou, China
May 14–16

EASTECWest Springfield,
USA
May 14–17

Mack-Teck

Budapest, Hungary
May 21–24

Moulding Expo

Stuttgart, Germany
May 22–25

BUTECHBusan, Korea

06

June
June 4–6

Zhengzhou
International
Hardware
Electrical
Exhibition

Zhengzhou, China
June 4–7

ITM Poland

Poznań, Poland
June 11–13

Fastener Expo
Shanghai

Shanghai, China
June 12–13

Amerimold

Rosemont, USA09

September
September 16–21

EMO

Hannover,
Germany
September 17–19

Fastener Show

Las Vegas, USA

10

October
October 1–3

TOOLEX

Sosnowiec, Poland
October 3–5

12

December
December 6–7

Fastenal
Employee Expo

Orlando, USA

EXPOLABSão Paulo, Brazil
October 8–10

METAVAK

Gorinchem,
Netherlands
October 11–13

CWMTE

Chengdu, China
October 23–26

MECT

Nagoya, Japan

June 14–17

IMTOS

New Delhi, India

SHAPE IT   OSG News 28

OSG Around the World
Employee Interview with

Katsutoshi Watanabe

Katsutoshi “Ben” Watanabe
Company Location: Singapore
Position: Engineering Manager
Joined OSG: 1997
Motto: “To be prudent yet fearless”

Tell us about your work & experience at OSG.
I studied electrical engineering in college and joined
OSG Corporation’s engineering division in 1997, morethan 20 years ago. In 2015, as Engineering Manager,
I was assigned to temporary transfer to OSG Asia in
Singapore to serve as Sales Engineering Manager for theSoutheast Asia region.

and sales, I also serve as general manager, taking chargeof pricing, ordering and inventory management.

Tell us about your daily routine.
Southeast Asia is a large region made up of manydifferent countries. My role changes depending uponlocation and needs. In general, I provide technicalsupport for the entire southeast Asia region. For
countries without an office, such as Pakistan, I would also
take on the role of a salesman. In addition to engineering

What is most challenging about your work?
I have worked mostly as an engineer throughout mycareer, so having sales responsibility now has becomea new challenge to me. As an engineer, my focus has
always been on tool performance. However, selling
tools often is not only about the cutting tool andperformance. The distributor, pricing and relationshipwith the end user all play a critical role in tool selection.
Simply providing technical support is insufficient. In
order to provide adequate products and services to theglobal market, we must learn about other aspects of thebusiness.

1

2

29 SHAPE IT   Meet OSG

What is unique about the Singapore division at OSG?
The atmosphere at OSG Asia in Singapore is very
energetic and friendly. We have many female staff at the
OSG Asia office and they are incredibly independent andself-driven. Company dinner is also a very big deal in the
Singapore culture.
What is your favorite OSG tool?
My favorite OSG tool is the AERO series for high-efficiency
milling of large aluminum aircraft components, which I
have personally developed. This series’ astonishing chip
evacuation capability always draw a great deal of attention
whenever I present this lineup of end mills to new end users.
The AERO series is a high-performance carbide end mill series designed for high-feed milling of aluminum alloys with superb surface finish.
Its high rigidity geometry enables the use of high-power equipment over 80kW for ultra-efficiency milling of large aluminum components.
The AERO series’ optimal flute shape enables trouble-free chip evacuation. Furthermore, its DLC coating provides the cutting tool with ashiny and smooth surface, optimal for aluminum alloy machining that requires welding resistance and lubricity. The AERO series is available
in various styles and sizes for both roughing and finishing processes.

How do you spend time on your day off?
Aside from playing badminton on a local team in
Singapore, I often travel overseas for leisure with my wife
during my time off work. Air fare is relatively inexpensive
in southeast Asia since all of the countries are very closeby one another. Thanks to the reasonable pricing andclose proximity, it’s very easy to have a weekend getaway overseas. After relocating to Singapore, I have beenable to meet many wonderful people from all aroundthe world. This experience is a great treasure of my life.

34

1. Back row, second from right, Watanabe poses for a group photo with his teammates during the Asian-Japanese badminton tournament
held in Thailand. In addition to Japan, Japanese who work in other Asian countries also participant in this annual tournament.
2. Watanabe and his wife pose for a photograph at the Samutprakarn Crocodile Farm and Zoo in Bangkok, Thailand.
3. Watanabe makes a huge leap at the Pinnacles Desert in Nambung National Park in Australia. During time off work, Watanabe often travels
overseas for leisure with his wife in the nearby region.
4. Far left, Watanabe enjoys dinner with the OSG Malaysia team during a business trip visit.

SHAPE IT   Meet OSG 30