A MAGAZINE FROM OSG | 2018 VOL. 2

SOLID CERAMIC END MILLSHigh Efficiency Machining

12

GLOBAL CUSTOMER REPORTS
Setting Track on Reliability 14
One-Step Drilling

18

EMPLOYEE INTERVIEWIn Shanghai, China

TOOL MASTER

CERTIFICATION
Staying ahead of the ever-changing world of manufacturing

426

Beyond 80
A Message from the President

March 26, 2018 marks OSG Corporation’s 80th anniversary. We would
like to express our heartfelt gratitude to the support of our customers,
business partners and shareholders for making it possible to welcome
this day.
Taking a moment to reflect upon this special milestone, the global
economy and our business environment have significantly evolvedin the last 20 years. China has grown into the second largest
economy after the United States with tremendous spending andmanufacturing power. It has earned the title of the “world’s factory”
with low production costs, abundant labor pool, vast talent base andbusiness ecosystem. In terms of technology, we are now living in an
era of Internet systems and services. Business is no longer dependent
on local customers for survival. Rather, enhanced connectivity has
revolutionized the method of sales, communication and the pace ofbusiness by opening the doorway to a worldwide audience for goods
and services.
Then, what kind of an era will it be in the next 20 years?
I suspect that the manufacturing industry will be significantly
transformed with electric vehicles (EVs) and the Internet of Things(IoT) taking center stage with greater emphasis on sustainability andresource sharing. In anticipation of a decline in the demand of cutting
tools for the manufacturing of automobile engines, OSG will endeavor
to expand its business in new markets, such as space, aerospace and the
medical industry. Looking ahead, OSG will continue its global expansion
while increasing its business in regrinding and recoating services.
We will advance into new markets other than cutting tools with our
superior coating technology. The method of sales will also evolve basedon specific market needs. Sales channel will likely be divided into two
key categories – tailored sales service with technical support and mass
distribution through the worldwide web to accommodate needs quickly
and easily. Nevertheless, all efforts must focus on customer demand inaccordance with changes in times.
OSG became 80 years old, but our vision is as clear as before. The secretto continuous growth is by confronting and staying ahead of change.
It is also crucial to listen to the voices and ideas of the new generation.
With versatility to accommodate evolving needs, I am confident thatOSG will be able to continue its path of success through and beyond our100th anniversary.

Norio Ishikawa
President & CEO of OSG Corporation

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CONTENTS
SHAPE IT 2018 VOL. 2

Features4 Tool Master Certification
18

Technical Insight

12 Solid Ceramic End Mills
Global Customer Report

14 Setting Track on Reliability

24

18 One-Step Drilling
Product Pickup

22 PSFL 4-Corner Anti-Chatter
		 Roughing Indexable Cutter
		 Series, AT-1 One Pass Thread
		Mill4

26

23 AD-LDS Carbide Starter Drill,
		 AE-VMS Anti-Vibration Carbide
		 End MillOSG News

24 Yana Factory Renovation

14

Meet OSG

26 Employee Interview
12
SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: August 2018
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
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FEATURE

OSG’s seminars are paid workshops available to both distributors and end users focused on in depth metal cutting
processes. Seminars are interactive and can provide great opportunities to share perspectives related to specifictopics, gaining expert knowledge and networking with other professionals.

TOOL MASTER CERTIFICATION
Staying ahead of the ever-changing world of manufacturing with continuing education
Reiko Masuhara, Naoko Sakata, OSG Corporation

The manufacturing industry is
consistently evolving through the new
discovery of materials and technologies.
In the last couple of decades, industries
have shifted emphasis on cleaner energy
and greater fuel efficiency, leading to theapplication of new materials, coatings,
and processing techniques that require
sophisticated cutting tools capable ofaccommodating these new requirements.
The solution for today may be a solutionof the past tomorrow. To meet thecomplexity of modern manufacturing,
continuing education is essential.
In addition to collateral materials such as workbooks, manuals or handouts, cutting
demonstrations are often included in seminars, allowing the participants to experience theinformation in person.
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CONTINUING EDUCATION PROGRAMSOSG Corporation currently offers three types of continuing education programs – e-learning, technical seminars and on-demand
training.

E-LEARNINGTECHNICAL SEMINARS

ON-DEMAND TRAINING

OSG’s comprehensive
e-learning programs are costefficient and flexible, allowing
participants to take courses
at their convenience. OSG
offers two types of e-learning
programs based on skill
level. The introductory levelis divided into six sections,covering the fundamentals oftaps, end mills, drills, gauges,
indexable and turning tools.
The advanced level is divided
into two sections, focusing on
drilling, threading and milling
applications.

OSG’s seminars are paid
workshops available to both
distributors and end users.
Every year, OSG offers a
combination of 1-day or 2-day
technical seminars nationallyin Japan. Programs areoffered based on three levels– beginner, intermediate
and advanced. Seminars
offered at the corporate
headquarters include live
demonstration at its recently
renovated technical centerand accommodation at thecompany’s very own Guest
House, which was completed
in 2012 to encouragecommunication among thetooling community.

OSG’s on-demand training isdesigned for end users who
are new to metal cutting. OSG
accommodates individual
requests by dispatching its
tooling experts to designatedlocations to provide tailored
training services.

OSG Corporation’s
lecture hall at thecorporate headquarters
in Aichi, Japan. Every
year, OSG offers a
combination of 1-dayor 2-day technicalseminars nationallyin Japan at various
locations, including its
corporate headquarters.

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FEATURE [cont.]

TOOL MASTER CERTIFICATION PROGRAM
In manufacturing, technology andmanagement practices change at
an ever-increasing rate, a gap isformed between the foundation
provided by an academic educationand the management competencies
required in today’s businessenvironment. The OSG Tool
Master Certification Program wasestablished in November 2017 tobridge this education gap.
OSG’s Tool Master Certification
Program involves the
documentation of successful
completion of metal cutting courses
and their associated examinations.
Upon the passing and completionof the certification requirement,
participants are certified as an
OSG Tool Master or an OSG Tool
Expert Adviser. This achievement
demonstrates an individual’s
expertise in the field of metal
cutting and personal commitment
to professional development.
OSG’s Tool Master Certification
Program ensures the competenceof metal cutting professionals
through a measurement of skills
and knowledge, which provides
reassurance to the cutting toolusers, knowing that the quality oftechnical support they receive fromcertified individuals is guaranteed
by OSG.

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SHAPE ITTECHNICAL SEMINAR

E-LEARNING

BasicThreading: Introductory

Intermediate

Drilling: Introductory

Advanced

Milling: Introductory

Tooling: Introductory

GaugesThreading Applications

Indexable Tooling
Turning Tools
Drilling & Threading Applications: Advanced
Milling Applications: Advanced

A sample list of courses required to be certified as an OSG Tool Master and OSG Tool Expert Adviser.

An example of an OSG Tool Master certification
card. Upon the passing and completion of thecertification requirement, participants may becertified as an OSG Tool Master or an OSG Tool
Expert Adviser.

LECTURER SNAPSHOTTakehiro Asai
Senior Customer Service
Supervisor

Profile:Asai joined OSG Corporationin 1980. During his 38-year
tenure at OSG, Asai has played acrucial role in multiple divisions,
including manufacturing,
research and development,
marketing and customer service.
Currently, Asai is the project
manager of OSG’s training
programs. He is one of the
key lecturers and has been an
instructor for 14 years. Asai also
serves as a visiting lecturer at
OSG Taiho in Taiwan and OSG
Shanghai in China.

“OSG’s training programs focus on metal cutting technologies. We rarely include sales
pitch in our training materials, and would include our products for demonstration
purposes only. Our courses not only cover cutting tools, but also materials, cutting oil,heat treatment, processing technologies, tool drawing, etc. All of the knowledge andtechniques acquired from the course apply to other cutting tool brands as well. The newcertification program is highly beneficial because end users can only receive quality
support from representatives with adequate metal cutting knowledge.”
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FEATURE [cont.]

TOOL MASTER CERTIFICATION PROGRAM

Participant Interview

Shingo Inoue
Yoshioka Kogyo Co., Ltd.
Sales Manager(Metal Cutting Division)

Certified OSG Tool MasterQ:
A:

How did you come across
OSG’s training programs?

My former job was in acompletely different field.
I knew nothing about
distributions nor the products that
we sell. I was encouraged to take theintroductory classes by my employer.
At the time, I attended one of theseminars held at the OSG Corporation
headquarters in Toyokawa, Aichi. I still
remember my instructor from then.

Q:A:

Why did you continue
taking classes upon
the completion of theintroductory courses?

The customers that weinteract with are often
metal cutting professionals
with a high degree of metal cutting
knowledge and skills. It may be difficult
to reach the same level. But in order topropose a solution, I feel that having
adequate knowledge is essential.
With basic knowledge, we can havea good conversation. Therefore, I wasdetermined to continue learning.

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Q:
A:

Which do you prefer –e-learning or technicalseminar in person?

From the perspective of
convenience, e-learning
is great because I can doit when I want to learn. On the other
hand, I find technical seminars to be
extremely valuable because they provide
actual demonstrations where we canexperience the actual tool selection,
testing and troubleshooting. The key
merit is being able to use our senses inperson – remembering the sound whenmachine trouble arises, the smell ofburnt material – which are things that
we cannot learn from textbooks nor
our daily work. With technical seminars,
participants get hands-on experiencefrom skilled experts on state-of-the-art
machines. Moreover, these workshops
provide opportunities to meet otherprofessionals in the same industry withdifferent background. It’s a lot of fun totake classes together and discuss thechallenges we face in our work. No many
how many seminars I attend, there arealways new discoveries.

Q:

Do you have any
experience where
you feel that you
have benefited from
attending these training
programs?

A:

When I visit a client and do
not know the answer to aquestion, I would revisit thecourse materials to try to figure it out
myself. Because sometimes it’s difficult
to ask other about them. I also use
the course materials for training new
employees. They are great materials.

Q:

What was yourimpression when
you first heard about
the OSG Tool Mastercertification program?

A:

I was surprised but was very
happy to hear about it. Fromthe perspective of the end
user, they would definitely prefer getting
helped by someone with adequate
knowledge than someone without. It
provides reassurance.

Q:
A:

Would you recommend
others to get certified?

Our company encourages
continuing education.
As it would also provide
improved services to our clients, I would
highly recommend other employees toparticipant.

Shingo Inoue poses for a photographat the port of Kobe. Many of
Yoshioka Kogyo’s customers are in
the shipbuilding industry and often
work with large-hole processing withdiameter over 100mm.

Yoshioka Kogyo’s headquarters in Kobe, Japan.

Company Profile

Yoshioka Kogyo Co., Ltd.
Established: 1956
Number of Employees: 30
Headquarters: Kobe City, Hyogo Prefecture, Japan
Core Products and Services: sales of cutting tools, manufacturing ofmachinery parts, installation of factory facilities and maintenance work,
sales and purchasing of second-hand machinerywww.yoshioka-kogyo.co.jp

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FEATURE [cont.]

TOOL MASTER CERTIFICATION PROGRAM

Participant Interview

Koji Watanabe

Right: From left to right, OSG
Corporation Marketing Supervisor
Reiko Masuhara, Ohtake President
Masahiro Okuwa, Ohtake SalesManager Koji Watanabe, OSG
Corporation Senior Customer
Service Supervisor Takehiro
Asai and OSG Corporation SalesManager Masashi Yano. There
have been approximately 15,000
participants in OSG’s training
program. As of spring 2018,
only 15 participants so far havequalified for the highest level Tool
Master certification. Koji Watanabefrom Ohtake is one of the few
individuals who have successfullyacquired the highest level Tool
Master certification from OSG.

Ohtake Co., Ltd.
Sales Manager

Certified OSG Tool MasterQ:A:

Why did you decide to
take the training courses
offered by OSG?

In order to distinguishourselves from other
distributors and to provide
the best possible services to our clients,
it’s our company policy to regularly
participate in continuing education
activities. I am not the only one who hastaken courses and seminars. All of ourstaff at Ohtake are also taking part inthese activities so that everyone would
be able to answer our clients’ inquires.

Q:
A:

What kind of benefits
have you gained fromtaking these courses?

When a customer asks aquestion, the ability toanswer right the way makes
a big difference. After taking all of themetal cutting courses, I can confidently
say that I am able to provide myclients’ with adequate advices. All theinformation taught from the courses arepractical and can be applied right theway in our daily work.

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Q:
A:

What is your impressionof the new Tool Mastercertification program?

There wasn’t any certification
program available when I
first started attending thetechnical seminars and online courses.
It’s also not very common from cutting
tool manufacturers in Japan. Many of
the courses offered by other cutting tool
manufacturers are targeted toward end
users. I think the certification programis a great motivation for us to keep
learning. At Ohtake, once we achieve
the OSG Tool Master certification, we
would include it in our business card.
Many customers may not know about
our company, but they are familiar with
OSG. So getting certified by OSG helps
increase our company’s creditability.

Q:A:

How do you feel about
this accomplishment?

I received my Tool Mastercertification in fall 2017,with credits that I haveaccumulated since 2007. It happened
that when I first joined the company,
OSG was offering a technical seminarin Sendai. After attending I was very
fascinated by the manufacturingindustry and was eager to learning more
about new technologies. I did not findattending seminars and taking courses
online to be stressful. Before I knew
it, I have successfully passed all of therequirements and was able to obtain thiscredential, which I feel very proud of.

Ohtake’s headquarters in Yamagata, Japan.

Company Profile

Ohtake Co., Ltd.
Established: 2002
Number of Employees: 13
Headquarters: Yamagata City, Yamagata Prefecture, Japan
Core Products and Services: sales of precision cutting tools, rolling
tools, measuring tools, auxiliary tools, machinery equipment andmachine oil
www.ohtakenet.com

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11

TECHNICAL INSIGHT

SOLID CERAMICEND MILLSHigh efficiency machining in heat resistant alloys
Kohichi Ohta, OSG Corporation Applications Engineer (End Mill Development Division)

Ceramic end mills have been developed as an effective
tooling solution for high efficiency roughing of heat-resistantsuper alloys (HRSA), which are widely used in the aerospaceand energy industries. HRSA are classified as hard materials
that are difficult to machine because of their excellent hightemperature strength and low thermal conductivity. HRSA
materials such as Inconel 718 have a tendency to soften whentemperature exceeds 700 Celsius, allowing easier cutting. As
ceramic end mills have high-temperature tolerance, they are aperfect fit for these hard materials.
Ceramic end mills are roughing tools that machine dry. Highefficiency roughing is achieved by applying the heat generated
from the fast, dry cutting as a part of the cutting mechanism
while machining in the designated temperature range where
the strength of nickel-based metal decreases.
OSG’s ceramic end mill series employs an optimum ceramic
grade ideal for high-speed machining at high-temperaturesin difficult-to-machine materials such as Inconel 718, withroughing efficiency dramatically surpassing carbide end mills.
Two types of ceramic end mills are included in the series – theCM-RMS peripheral cutting edge type and CM-CRE end cuttingedge type.
Compared to carbide end mills, ceramic end mills are superior
in hardness at high-temperatures. However, ceramic end mills’
resistance against transverse stress are less than half of carbide
end mills, making them easily prone to unexpected breakage
when used under inappropriate cutting conditions. To
minimize sudden breakage, OSG’s CM-RMS features optimum
flute geometry to enable smooth chip evacuation even ataggressive cutting condition. Its negative cutter form increases
cutting edge rigidity to enable long tool life as illustrated infigures 1 and 2. The CM-RMS is available in 4-or 6-cutting edge
specification to accommodate individual application needs.

OSG’s ceramic end mill series employs an optimum ceramic
grade ideal for high-speed machining at high-temperatures indifficult-to-machine materials such as Inconel 718, with roughing
efficiency surpassing carbide end mills.
12

SHAPE ITThe CM-CRE end cutting edge type ceramic end mill does not
only excel in flat surface milling, but also in 3D applications,such as the machining of turbine blades. Its large-diameter
specification reduces the risk of breakage during machining
and enables optimum cutting speed without being restrictedby the capability of the machining center. Furthermore, the
CM-CRE is regrindable and can be reincarnated by cutting

away the used portion.
Ceramic end mills enable higher cutting
speeds and longer tool life versus
conventional carbide end mills, which
would not be able to tolerate suchhigh-temperature machining condition.
For manufacturers who are in search ofsignificantly greater productivity in hardrough milling operations, solid ceramicend mills may be the ultimate toolingsolution.

CM-RMS 4-flute peripheral
cutting edge type ceramic end millis ideal for side milling, slot milling,helical milling, contour milling andramping. The CM-RMS 6-flute peripheral cuttingedge type ceramic end mill is suitable for side
milling, helical milling and contour milling.

Figure 1

Continuous Use is Possible with Low Level of Cutting Chip Welding
4-Flute Peripheral Cutting Edge Type
Tool
Tool
Work Material
Work
Material
Machining
Machining

CM-RMS
CM-RMS

Competitor
Competitor
4-Flute

φ12× R1.5×4Z
Ø12xR1.5x4Z

Milling Length (m)Milling Length (m)4-Flute0

Inconel（(45HRC)
45HRC）
Inconel718
718
Milling spirally
fromthe outer
periphery
MillingSpirallyinward
Inwardfrom
Outer
Periphery

Cutting Speed
Cutting
Speed

500m/min（13,260min
500m/min(13,260min-1-1）
)

Feed
Feed

3,182mm/min(0.06mm/t)）
3,182mm/min（0.06mm/t

Depth
Cut
Depth ofof
Cut

p=7.2mm aae=1.2mm
p=1.2mm
aap=7.2mm

Coolant
Coolant

AirBlow
Blow
Air

MachineMachineVerticalMachining
Center
Vertical Machining
Center

0

10

10

20

20

30

30

40

40

50

CM-RMS

50

Still Running

CM-RMS

Still Running

Competitor

Wear

Wear

Competitor

φ153 × 100

Cutter path

Figure 2

Stable Machining Free of Breakage
6-Flute Peripheral Cutting Edge Type
Tool
Work Material
Machining

CM-RMS

Competitor
6-FluteØ12xR1.5x6Z

Milling Length (m)0Inconel 718 (45HRC)
Milling Spirally Inward from Outer Periphery

Cutting Speed

500m/min (13,260min )Feed3,182mm/min (0.06mm/t)

Depth of Cut

ap=7.2mm ap=1.2mm

2040

CM-RMS

60

80

100

Still Running-1

Coolant

Air Blow

MachineVertical Machining Center

Competitor

Breakage

SHAPE IT13GLOBAL CUSTOMERREPORTSETTING TRACK ON

RELI BILITY

All-purpose A-Tap stops tool breakage in hand tapping
process of rolling stock production
Gabriel Fernando Gialorenço, OSG Sulamericana

Hyundai Rotem’s Brazil production plant was established in 2015 in
Araraquara, São Paulo. Hyundai Rotem Brasil currently employs 136 staff
and has a total production space of 157,850.08-meter-square.

From left to right: Hyundai Rotem Tool Manager Olavio Almeida,
OSG Sulamericana Applications Technician Gabriel Fernando
Gialorenço, Hyundai Rotem Purchaser Giulia Cardoso Fiorotto,
Hyundai Rotem Purchaser Lidiane Montanari and Hyundai Rotem
Production Assistant Marcos Moreira.
14

SHAPE ITRail transport is one of the mostsustainable mode of transports available
today due to its cost effectiveness,reliability and minimal impact to theenvironment. Developed to handle
both freight and passenger traffic, railtransport demand continues to risearound the world in response to rapid
urban expansion and globalization.
Owned by the Hyundai Motor Group,
Hyundai Rotem is one of the world’s
largest railway system providers
renowned for its world-class technology
and quality. It supplies a majority ofSouth Korea’s rolling stocks and plays
a leading role in the developmentof railway systems in 50 countries
worldwide, including large metropolitan
cities such as Hong Kong, Vancouver andPhiladelphia.
Manufacturers in the railway industry
are constantly under pressure to bolster
infrastructures, enhance services,while simultaneously achieve overall
cost-reductions. Hyundai Rotem
was confronted with cost-reduction

challenges in the production of rollingstocks at its Brazil production plant,
which was established in 2015 in
Araraquara, São Paulo. Hyundai Rotem
Brasil currently employs 136 staff
and has a total production space of
157,850.08-meter-square.
Hyundai Rotem has been carryingout the assembly of trains at their
Araraquara plant since August
2015. Rolling stocks, which are rail
vehicles used in the rail transportindustry, are key products of Hyundai
Rotem Brasil. Made of 304 stainlesssteel, each rolling stock requires
multiple threading processes in the
train composition, such as the door
groundsills, panels, seats and otherstructural parts. Threading processes
are required for new rolling stocks aswell as old ones that are in need ofrepair.
Hyundai Rotem’s production volume
varies based on the number of trains
being delivered, damaged parts andrespective exchanges. On average,

From Top: The interior of a rolling stock, which is arail vehicle used in the rail transport industry, and isa key product of Hyundai Rotem Brasil.
Hyundai Rotem is one of the world’s largest railway
system providers renowned for its world-classtechnology and quality.
Made of 304 stainless steel, each rolling stock
requires multiple threading processes in the train
composition, such as the door groundsills, panels,
seats and other structural parts.
Left: Threading processes are required for new
rolling stocks as well as old ones that are in needof repair.

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GLOBAL CUSTOMERREPORT [cont.]

Hyundai Rotem’s previous tooling choice averaged 30 threads per tool. By switching to OSG’s A-Tap series,
Hyundai Rotem is able to achieve 10 times the tool life under identical cutting condition.

Hyundai Rotem performs approximately
15,000 threads per month per thread
size of M4, M5 and M6 in 6H tolerance
according to DIN 371 standard. It
is estimated that 1,900 threads are
required for each train composition. Allof the processes require the threadingof through-holes in depth variations of
4mm to 25mm. The threading process
involves the use of pneumatic andelectric drill drivers at cutting speed of
2,500 RPM. For the lubricant, a cutting
fluid composed of highly refined mineral
oil with anti-wear, anti-seize and extreme
pressure additives is used.
Hyundai Rotem was originally using HSS
plug taps with OX surface treatment for
16

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their production of rolling stock. Thesestraight flute general purpose hand taps
are commonly used for through holetapping without using a starter taper
tap. Hyundai Rotem was experiencing
constant tool breakage throughout its
production process with the plug taps.
Tool breakage is a serious production
obstacle as it is costly, time-consuming,and may cause damage to the part. As
a company that is always proactively
responding to growing global demandand changing market environment,
Hyundai Rotem Manager DanielBitencorte and Area Foreman Paulo
Caires, who supervise the productionof rolling stock, were in search of analternative solution to improve tool life

It is estimated that 1,900 threads are required for each train
composition.

and overall cost. An opportunity for new
tooling trial came about when an OSG
application technician gave Hyundai
Rotem a visit. After a throughout
evaluation of the application, OSG
recommended the A-Tap A-POT M4(EDP# 48145144), A-POT M5 (EDP#
48145149) and A-POT M6 (EDP#
48145155).
The A-Tap is an all-purpose tap series
developed to accommodate a wide
variety of materials and machining
environments, helping manufacturers
simplify tool management. The A-Tap
series includes the A-SFT spiral taps forblind holes and the A-POT point taps forthrough holes.

To enable high speed machining, theA-Tap series incorporates a uniquecutting edge design that emphasizes
sharpness. Powdered metal HSS and
OSG’s patented V coating are employedin this series to enhance wear resistance.
Not only does the A-Tap series perform
well in general steel, it also excels indifficult-to-machine materials suchas stainless steel and mild steel. As
an all-purpose tap series, the A-Tap
is compatible with various types ofmachining equipment – from manual
drilling machines to the latest advanced
machining centers.
With the previous tooling choice,
Hyundai Rotem was using approximately

600 taps per month with each tap
averaging 30 threads in tool life. Whenperforming the same work with the
A-Tap, on the other hand, each tool isable to complete 300 threads, which
is 10 times the durability, resulting
in excellent cost savings for Hyundai
Rotem.
By switching to OSG’s A-Tap series,
Hyundai Rotem is able to enhance its
operation’s stability and quality control.
Moreover, the services that come alongwith the quality products – prompt
response and problem-solving ability –makes OSG a reliable partner in Hyundai
Rotem’s global growth strategy.
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GLOBAL CUSTOMERREPORT

ONE-STEP DRILLINGADF flat drill eliminates
starter hole to simplify
machining process and tool
management
Siriruk Thammajit, OSG Thailand

Image of the rotor part in S45C after
processing. Asia Precision Public Company
Limited was initially machining these parts
with the use of a drill and an end mill. Afterswitching to the ADF flat drill, Asia Precision isable to consolidate the process, significantly
reducing processing time.

Machining flat-bottom holes
traditionally required the use of a drill
and an end mill. The drill is used in the
preliminary center drilling operation tocreate a start hole, followed by the useof an end mill to complete the process.
Not only is the utilization of two tools
costly, additional setup time is also
required to exchange between tools.
When machining flat-bottom holes,
maintaining consistent hole quality canalso be a challenge. Burrs are common
problems particularly in thin plates andunstable cutting environment.
The ADF carbide flat drill, one of OSG
Corporation’s latest drilling innovations,eliminates all of the mentioned
machining challenges with one-step
drilling, providing manufactures with
18

SHAPE ITsignificantly improved processing
efficiency and work quality. Asia
Precision Public Company Limited is
one of the manufacturers who has
recently leveraged the ADF’s superior
performance in their production process.
Established in 1994, Asia Precision is
one of Thailand’s leading precision
metal component manufacturers
serving customers in various industries,
including automotive, camera,compressor, machinery, medical, officeautomation, telecommunication andaerospace. Located in Muang, Chonburi,
Thailand, Asia Precision’s capabilities
include cold forging, precision
machining, gear making, induction
hardening, anodizing, aluminum die
casting, heat treatment, hot forging andcomponent assembly. Asia Precision’s
product offering range from cam ring,lens housing, connector, union bearing,
piston, valve, drive shaft, flange, bracket,
pin, just to name a few.

Asia Precision’s Senior Manager Prasit
Mulgunee welcomed the opportunity inhopes of improving work efficiency.

Asia Precision has four manufacturing
facilities in Thailand with an estimate
total production space of 20,000 square
meters and over 500 employees. The
staff at Asia Precision are constantly
improving production process
to generate cost savings for theircustomers.

The ADF is able to consolidate themachining process for Asia Precision’s
application, completely eliminating the

The opportunity to evaluate new tooling
options came about when Asia Precision
was assigned with a new project
involving automotive parts. The work
involves the machining of electric oilpump rotor parts in S45C. Each vehicle
requires a piece of the rotor part. The
monthly production is estimated to bearound 26,000 pieces. Each workpiecerequires the machining of two slots,measured 10mm in diameter and 28mm
in depth. The machining center used
for this particular production is the
Yamazaki Giken YM-850. Initially, Asia
Precision was processing these partsutilizing a 7.5mm diameter carbide drill
for center drilling, followed by another
2-flute 10mm diameter carbide end millto complete the hole.
When OSG recommended the 10mm
diameter ADF-2D for one-step drilling,

Unlike conventional drills, OSG’s ADF
carbide flat drill is capable of creating
holes in inclined and contoured surfaces
without requiring a start hole. The ADF’s
unique balanced form and cutting edge
enable reduced cutting forces withsmaller chips and stable hole entry withminimal burr. With the addition of OSG’sproprietary EgiAs coating, tool life canbe prolonged with excellent heat andwear resistance.
The ADF is engineered for a wide
variety of drilling applications, including
inclined surfaces, curved surfaces,
counterboring, eccentric holes, half-holeand thin plates. It is suitable for common
materials such as carbon steel, alloysteel, hardened steel up to 35 HRC, andcast iron.

The ADF is a multi-purpose flat drill series engineered formachining inclined surfaces and counterboring applications.
Unlike conventional drills, the ADF flat drill is capable ofcreating holes in inclined and contoured surfaces without
requiring a start hole.
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GLOBAL CUSTOMERREPORT [cont.]

OSG Thailand Sales Representative Siriruk Thammajit explains the features and benefits of the ADF flat drill to Asia Precision Senior Manager Prasit Mulgunee.

preliminary center drilling operation.
The ADF was also tested against acompetitor tool for a durability. At
the end of the trial, the ADF was able
to more than double the life of thecompetitor drill, achieving 500 pieces
versus the competitor’s 200 pieces.
“The ADF demonstrated overwhelmingly
superior performance versus theprevious procedure,” said Siriruk
Thammajit, OSG Thailand Sales
Representative.
A rotor part in S45C before processing. Each
workpiece requires the machining of two slots,measured 10mm in diameter and 28mm in depth.
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“Asia Precision is now able to combine
two operations into one. Taken the timerequired for tool change, the ADF is able

to reduce the processing time by near 50
percent, and our customer couldn’t be
more satisfy,” said Thammajit.
As a manufacturer who prides itself asa precision metal component specialist,
Asia Precision is always seeking todevelop new processing solutions
to meet the ever-growing customer
requirements. The ADF has proven to
be a reliable partner in Asia Precision’s
endeavor for improving quality, reducing
machining time and simplifying tool
management.

Asia Precision Public Company Limited manufacturesapproximately 26,000 pieces of rotor part made in
S45C monthly.

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21

PRODUCT PICKUPOSG PHOENIX PSFL

4-Corner Anti-Chatter Roughing Indexable Cutter Series

The OSG Phoenix PSFL is a 4-corner roughing
indexable cutter developed for high-productivity
milling. The PSFL features a special body design
with unequal lead alignment andunequal spacing teeth to suppress
chattering even in deep milling
applications. The PSFL’s highdurability 4-corner insert provides economical
yet powerful solution for face milling, side millingand slotting operations. Its 3-dimensional breakerinsert’s sharp cutting edge and large positive
rake angle reduce cutting resistance, allowing
optimum performance even under aggressive
cutting condition. Four insert types are available
to accommodate a wide range of work materials– from general steel to difficult-to-machinematerials.

AT-1

Revolutionary 1-Pass Thread Mill for High-Quality Threading

Conventional thread mills often require
several passes to generate a thread. The AT-1’s
revolutionary capability togenerate threads in one
pass lies in its unique toolgeometry. The unequal
spacing and variable lead fluteof the AT-1 minimizes vibration,
thereby enables superior andconsistent surface finish.
Conventional right-hand helix
thread mill is prone to deflection
as the cutting process begins
from the tip. In contrast, a firstof its kind with a patent in Japanin the thread mill category, theAT-1’s right-hand cut and left22

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hand helix geometry begins the cutting processfrom the shank side, thereby reduces deflection.
With the elimination of zero-cutting, which isused for the correction of deflection, longer tool
life can be achieved.
Made of ultra-fine grain carbide paired with OSG’soriginal EgiAs coating, tool life can be further
prolonged with improved wear resistance andtoughness. The AT-1’s ability to generate threads
in one pass reduces machining time, making
it a highly efficient thread milling solution incomparison to right-hand helix thread mills.
The AT-1 is designed to excel in a wide range ofwork materials, including carbon steel, alloy steel,stainless steel, cast iron and non-ferrous metal.

AE-VMSØ16, 20, 25 Short Length & Ø 1, 1.5, 2, 2.5 Stub Length Added to Anti-Vibration
Carbide End Mill AE-VMS Series

Short length in diameter 16, 20, 25 and stub
length in diameter 1, 1.5, 2, 2.5 have 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.
The AE-VMS’ sharp positive rake angle geometry
significantly reduces cutting force to minimize
tool wear and potential damage to the workpieceeven under aggressive cutting conditions.
Chattering is minimized with the AE-VMS’
unequal spacing of teeth and variable-leadgeometry. Furthermore, its unique flute form
helps facilitate trouble-free chip evacuation to
enable stable and consistent performance. With

the AE-VMS’ high tool rigidity, the occurrence ofburrs can be suppressed to ensure high milling
accuracy. With the addition of OSG’s original
DUARISE coating, tool life can be enhanced by
its excellent lubricity, superior friction-resistanceand high oxidation temperature qualities. The
DUARISE coating’s multi-layer construction
minimizes thermal cracks, allowing the AE-VMS
to excel even in water-soluble oil.
Available in square, radius, stub length and longneck, the AE-VMS is designed to accommodatea wide range of milling operations including
slotting, side milling, helical milling, contour
milling and ramping in stainless steel, cast iron,carbon steel, alloy steel and hardened steel (up to
40 HRC).

AD-LDS

EgiAs Coated Carbide Starter Drill for Centering and Chamfering Operations

The AD-LDS carbide starter drill is OSG’slatest innovation for high precision
centering and 90-degree chamfering
operations. Carbide starter drill enables
higher machining speed in comparison
to HSS products. Coated with OSG’soriginal EgiAs coating, the AD-LDS isconstructed with extreme toughness
and high wear resistance for long tool
life. The AD-LDS’ cutting geometry isengineered with superior sharpness
and high chipping resistance to allow
the creation of perfectly round starterhole with minimal burrs, which enables
trouble-free secondary operations.

SHAPE IT23

OSG NEWSYana Factory

RENOVATION
The world’s largest tap plant gets a make-over with new lobby
and exhibition space

The main lobby of the Yana tap factory.
24

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Above: The Yana tap factory’s newly
renovated exhibition space.

DID YOU KNOW?

Right: OSG’s Yana Factory is theworld’s largest tap plant, with anestimate maximum production
volume of 1.5 million taps per month.

OSG Corporation’s Yana Factory – theworld’s largest tap plant – received a
make-over earlier in the year, with arenovated lobby and new exhibition
space on its second floor.
OSG has been manufacturing taps since
its founding in 1938. In commemorationof its 80th anniversary, the Yana tap
factory was the first facility to berenovated in 2018 with an objective tofurther encourage communications withmembers of the manufacturing industry.
The newly renovated exhibition spaceembraces the principle of minimalism– removing unnecessary internal walls,
stripping down to the core essential tofocus on the space’s purpose and on

OSG’s Yana Factory is thelargest tap manufacturing plantin the world.

the beauty of its carefully selected
furnishings. Color combinations havealso been kept to a minimum to enhance
the serene and balanced environment.
The key display cases have been
designed using basic geometric forms,
elements without decorations andsimple materials. Furthermore, a 2.4 by
1.4 meters monitor is mounted on thewall of the exhibition area to display
some of OSG’s latest tooling innovationsin action.
The brightly lit and streamlined interior
design aims to encourage creativity.
We hope visitors can appreciate the
newly renovated space’s simplicity andtimeless concept.

• Maximum Production
		Volume: 1.5 million taps
		 per month• Total Land Area:		77,226-square-meter• Production Space:		29,000-square-meter• Number of Employees:
		460• Units of Machines:
		894

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MEET OSG

OSG Around
the World

Vis Huang
Employee Interview

OSG Corporation was founded
in 1938, more than 80 years ago.
Today OSG holds the No. 1 positionin the Japanese cutting tool market
as well as a top-ranking position
globally, with a production, sales
and technical network spanning
33 countries. Our commitment toinnovation, services, total solutions
and out-of-the-box thinking
has contributed to our immense
success today. However, without
our employees, none of it would bepossible. We truly believe that ouremployees are one of the greatest
assets of the company. In thissection, we will introduce our teammembers from around the world.

Vis HuangCompany Location:
Shanghai, China
Position:
Marketing Manager
Joined OSG:
2006
Motto:“Achievements are reached byhard work rather than play;
actions should be taken after athorough thinking process rather
than a causal decision.”

26

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Huang (far right) and her marketing team pose for a photograph at the OSG Shanghai office.

Tell Us About Your Work & Experience at OSG:
I studied international trade during college and joined OSG Shanghai’smarketing division in 2006. I currently serve as OSG Shanghai’s Marketing
Manager, overseeing the production of all promotional materials andmarketing campaigns in both print and digital. In addition to productpromotion, my role also involves market research and event planning, suchas exhibitions and seminars.
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Tell us about your daily
routine.
The work of our marketing
department can bring a great senseof accomplishment. I work with ourmarketing staff on a daily basis todevelop marketing plans for various
media channels. It is very rewarding to
be able to see the progress and resultsfrom start to finish. For each marketing
project, all members would brainstorm
together and work toward a common
goal. Our marketing department places
great emphasis on team work. It also
makes us feel like family.

What is unique about the Chinese division at OSG?
The atmosphere at OSG Shanghai is very genuine. This quality has attracted me towork here for 12 years. We are blessed with a leader who always wear a smile and isfriendly to everyone he meets. Our staff gets along well and always look out for one
another, which creates a family-like environment.

What is your favorite OSG tool?
The A-Tap is my favorite OSG tool. This product isthe pride of OSG. The A-Tap is known for its superior
chip evacuation capability. It is an all-purpose tap
series developed to accommodate a wide variety
of materials and machining environments, helping
manufacturers simplify tool management. Every time
I introduce the A-Tap at an exhibition or seminar, I feel
confident and proud to explain its features and benefits.
It is a marvelous tool that stands out from the crowd,
providing great customer satisfaction and success to OSG.
The A-Tap is an all-purpose tap series developed to accommodate awide variety of materials and machining environments with superior
chip evacuation capability.

The Lunar New Yearis one of the mostprominent festivals
in China. Huang andher family visited the
local temple earlier thisFebruary to pray for aprosperous new year.

Huang and her sevenyear-old daughter enjoy
time together during theholiday.

How do you spend time on your day off?
During my time off work, I would spend most of my time with family. I have aseven-year-old daughter and she is the treasure of my life. During the holidays,
being able to spend every minute with her brings me the most joy. We enjoy
playing games, reading and making desserts at home, or going outdoor to
enjoy nature.

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27

OSG
Phoenix
PSFL
4-corner anti-chatter roughing indexable cutter series
Scan for details.