OSG Global Tooling Magazine

WINTER 2021

Productivity of
the Highest Level
AERO milling cutter and Safe-LockTM
system enable ultra-high-speed
machining of large aluminum
aircraft components
Technical InsightADO-40D and 50D
Coolant-ThroughCarbide Long Drills

Customer Report

Tailored Solution
OSG custom carbide tap
eliminates chip evacuation issues
in automotive pipe production

Meet OSG

Employee Interview
in Canada

Leading Businesses in the New Normal
A Message from the President
2020 has become one of the most challenging years
in the 21st century, where businesses are forced
to operate in a rapidly changing environment. The
coronavirus pandemic did more damage to theworld economy than the Lehman financial crisis overa decade ago. With the pressure of lockdown andongoing uncertainty in all factors of life, impacts arefelt across the globe. On both corporate level andindividual level, activities that were once considered‘normal’ can no longer be carried out with ease. Whena coronavirus vaccine is developed with treatment
method established, ‘normal activities’ can be resumed.
However, the transformed business models andpractices will continue to take root in what is now
known as the ‘new normal.’
Even after we have entered into the post-crisis period,
this ‘new normal’ will likely remain to become the newstandard across business sectors. However, products
and services must not be driven into a uniform
approach that lack attention to individual differences.
Sustainable growth can only be achieved throughinnovation and by responding effectively to change.
Under the new norm, we must continue to implement
greater differentiation and deliver new values to ourclients.
In 2021, OSG will strive to create values that go beyondthe ‘new norm,’ building resilience to help the company
and manufacturers around the world to thrive in thisnew reality.

Norio Ishikawa
President & CEO of OSG Corporation

1

SHAPE IT   ﻿CONTENTS Feature
SHAPE ITWINTER 2021

3 Productivity of the Highest Level

Technical Insight
11 ADO-40D and 50D Coolant-Through Carbide Long Drills

Customer Report
17 Tailored Solution
19 High Speed Machining

Product Pickup
21 AT-2 Helical Drilling and Threading Combo Tool for High-Hardness Steels, AM-EBT
and AM-CRE Carbide End Mills for Additive Manufacturing Applications

22 Phoenix PSTW 6-Corner Shoulder Milling Cutter, AD and ADO Carbide Drill Series

OSG News
23 OSG Web Showroom

Meet OSG
25 Employee Interview in Canada

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: January 2021
Rights: Reproduction of the articles and photographs without permission is strictly prohibited.

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

SHAPE IT   ﻿

2

From left, Kentaro Masutani from Primetals
Technologies Japan, Masaru Fujinaga, Osamu
Nakano, Yusuke Kamio, Ayakatsu Eki, Takanori
Terasako, Hirokazu Unno, Noriaki Sugihara and
Masaki Murakami from MHI.

Members of the 777X project pose for a photograph in front of the Makino A6 high-speed and high power 5-axis horizontal machining
center at MHI’s Eba Factory in Hiroshima, Japan.

Productivity of the Highest Level
AERO milling cutter and Safe-LockTM system enable ultra-high-speed machining oflarge aluminum aircraft parts
Kanako Mizutani
OSG Corporation
Aluminum in general is a material with good machinability
and is often processed under more aggressive cutting
conditions than steel. In recent years, there is a growing
demand for ultra-high-speed machining of large-sizedaluminum parts using high-power milling machines
exceeding 80 kW especially in the aerospace industry. In
order to meet the demand of heavy duty machining thatmaximizes the capabilities of advanced machining centers,
however, a number of challenges with regard to cutting
tools and tool holders must be overcome.

Reduced Machining Accuracy
Ultra-high-speed machining requires a larger cutting
load than usual. If the rigidity of the tool or tool
holder is insufficient, deflection or chattering may
occur during machining. In addition, runout of the
cutting edge will increase due to the centrifugal force,
which may result in undesirable machined surface
quality and dimensional accuracy.

Tool Damage and Breakage
Especially notable under aggressive cutting conditions,as the machine’s spindle speed increases, the centrifugal
force on the tool mounted at the end of the spindle will also
increase. Therefore, even if the runout accuracy of the tool
cutting edge is initially controlled, runout may occur during
rotation. This would result in a shorter tool life and may
cause chipping or sudden tool breakage in some cases.
3

SHAPE IT   Feature

A photograph of the Boeing 777X.
Photo courtesy of The Boeing Company.

With the launch of the Boeing passenger aircraft 777X project, MHI decided to introduce a 120 kW high-speed and high power 5-axis
horizontal machining center, the Makino A6, with a maximum spindle speed of 33,000 min-1 to improve productivity substantially.

Tool Pull Out

MHI 777X Project Member Spotlight

When the cutting load increases, a large force
is applied to the tool in the direction awayfrom the spindle. The axial and rotational forces
can cause the cutting tool to rotate in the tool
holder. In the worst case, the cutter is pulled outof the chuck. Under such a scenario, not onlyis the tool damaged, the machined workpiece
may also suffer defects. Conventional side lockmechanism for tool pull out may deteriorate
runout accuracy.

Reduced Spindle Life
When the tool holder and cutter receive a large
centrifugal force due to high-speed rotation,a large load is also applied to the spindle. This
reduces the life of the spindle and necessitates
frequent replacement.
In order to solve the above problems, a toolingsystem with high rigidity and ability to minimize
centrifugal force is necessary. In addition,
heat and a large amount of cutting chips are
generated during machining, so the cutter must
be equipped with welding resistance, lubricity,and excellent chip evacuation capabilities.

Jun EtoHirokazu Unno

Eto is an MHI engineer with 10
years of experience in aircraft
parts machining. He belongs to
the Manufacturing Engineering
Department’s Tool Design Teamin Nagoya and is a key memberof the 777X project. Afterlaunching the 777X project, Eto
joins the Mitsubishi SpaceJetdevelopment team and has
been in charge of technicaldevelopment of parts machining
since July 2020.

Unno is an MHI engineer withmore than 20 years of experiencein aircraft parts machining,
cutting tools and jig design. He
belongs to the Manufacturing
Engineering Department’s Tool
Design Team in Nagoya and is a
key member of the 777X project.
Even now, Unno visits the Eba
Factory in Hiroshima regularly tocontinue to support machining
process improvement of the
777X project.

SHAPE IT   Feature

4

1 2

1. From left, Primetals Technologies Japan Technician Kentaro Masutani and MHI technician Takanori Terasako discuss details of theapplication for the 777X project.
2. Based on cutting trial results, MHI selected OSG’s AERO end mill series for the cutter.

Mitsubishi Heavy Industries, Ltd.
Founded in 1884, Mitsubishi Heavy Industries, Ltd. (MHI)
is a multinational company headquartered in Tokyo,
Japan. MHI has a proven track record in a wide range ofindustries, from shipbuilding, transportation systems, civil
aircraft, infrastructure such as power generation systems,
to space systems.
In the aircraft field, MHI’s Oe Factory in Nagoya and Eba
Factory in Hiroshima manufacture large parts such as themain wings of the Boeing 787 and sections of the fuselageof the Boeing 777. The Oe Factory and Eba Factory havea site area of 387,700-square-meter and 669,908-squaremeter respectively.

MHI’s 777X project team and two applications engineers from
Makino pose for a photograph with a prototype part at the 777X
1st Part Completion Ceremony at the Eba Factory in Hiroshima on
October 31, 2016. Photo courtesy of MHI.

Currently, MHI is actively involved in the manufacturingof the Boeing passenger aircraft 777X. MHI is responsible
for producing sections of the rear and tail fuselage as wellas the passenger entry doors. Among them, OSG cutting
tools are used for the roughing and finishing of large
aluminum structural parts (about 4 meters in size) of therear fuselage panels.
“For the 777X, there are approximately 100 new large
components required to be made,” said Hirokazu Unno, an
MHI lead engineer with more than 20 years of experienceat the Manufacturing Engineering Department’s Tool
Design Team.

“Traditional method would have been to start witha large number of machines and suppliers,” Unno
explains. “However, to reduce costs, we shifted focus toincreasing productivity per machine and start up withas few facilities as possible.”5

SHAPE IT   Feature

The AERO-O-ETS end mill is apart of OSG’s AERO end millseries, which is designed tomaximize the full potential ofhigh-performance equipment
over 80 kW. The AERO series ismost ideal for high-efficiency
machining of large aluminum
aircraft components.

3

3. From left, HAIMER Area Sales Manager Tom Yamashita explains features of the HAIMER Power Clamp shrink fit machine to MHI’s
Osamu Nakano.

Like Unno, Jun Eto is also a key member of the
777X project from the start and belongs to thesame department with 10 years of experiencein aircraft parts machining.
“Speed is an important factor when we are
required to produce large numbers of newparts,” Eto adds. “We opted for a new machining
process in order to further improve precisionand reduce machining time.”

A6, with a maximum speed of 33,000 min-1 to improve
productivity substantially.
“We felt that the 777X project was a great opportunity tointroduce some of the best equipment in the world,” said Eto.
Based on preliminary research in Japan and overseas, theproject team knew for a fact that the machining center ishighly reliable. The challenge was how to operate it.

According to Eto, when working with new partsand machining processes, troubles relating to
the workpiece often occur at startup. “So, we
have to eliminate all potential troubles on thetool side,” said Eto.
In the past, MHI had introduced a horizontal
machining center with up to 30,000 min-1
spindle speed for heavy duty machining.
However, full benefits of high-speed
machining could not be obtained with themachine, conventional tool and tool holder
at the time. Thus, the company mainly usedvertical machining centers with less than
20,000 min-1 spindle speed for the machiningof aluminum parts.
With the launch of the Boeing passenger
aircraft 777X project, MHI decided to introduce
a 120 kW high-speed and high power 5-axis
horizontal machining center, the Makino

MHI installed the HAIMER Tool Management system at its Eba Factory – aworking area specifically designed for tool storage, assembly, presetting
and administration. Preset areas have an image of being dark and are
typically situated at the corner of a factory. To eliminate this common
perception, MHI purposely installed the Tool Management system asa bright, clean and open area at the factory entrance to symbolize thecompany’s attitude toward tool management and commitment to quality.

SHAPE IT   Feature

6

Takanori Terasako, MHI technician and a member of the 777X project, uses the HAIMER Tool Dynamic balancing machine at the Eba Factoryin Hiroshima.

“High-speed milling machines offer high performance,
but it is essential to pay close attention to the operating
cost including the spindle unit,” said Eto. “In order toincrease productivity and reduce operating costs, it isnecessary to control not only the machine, but the total
performance from the spindle to the tool tip.”
For the tooling, MHI conducted in-house researchand cutting trials in advance to select the mostappropriate cutter and tool holder. In order to achieve
stable production at ultra-high-speed machining ofover 30,000 min-1, it is utmost critical to minimize thevariation in performance of the cutting tool and tool
holder. Specifically, it is crucial to control the variation
when the tool is preset in the tool holder.
The start of production was under a tight schedule atthe time. It was important that the tooling used haveminimal difference between the process simulationand the actual performance. The more consistent theperformance, the sooner MHI would be able to start up
the actual machine without the need to conduct moretests for cutting condition settings. Among the toolsthat MHI have tested was OSG’s AERO end mill series,
which the company has been using for a long period oftime. The tools from this series have also demonstrated
7

SHAPE IT   Feature

good productivity and minimal difference from thesimulation in field trials by machine tool manufacturers.
Based on the results of the cutting trials, MHI selected
OSG’s AERO end mill series for the cutter.
OSG’s AERO end mill series is designed to maximize thefull potential of high-performance equipment over 80
kW. The AERO series is most ideal for high-efficiency
machining of large aluminum aircraft components. The
AERO-O-ETS 3-flute short type carbide end mill withinternal coolant hole can be used for roughing up tofinishing. It features a sharp cutting edge specification
to enable excellent cutting, and an optimal flute
geometry to facilitate trouble-free chip evacuation.
Furthermore, its DLC coating provides a shiny surface
with optimized end mill performance particularly inaluminum alloys that require welding resistance andlubricity. Its thin coating layer enables a sharp cuttingedge, which contributes to smooth and superb surface
finish, even in high-feed milling.
For the tool holder, MHI selected a high rigidity andprecision shrink fit holder developed by German
manufacturer HAIMER, as well as their Safe-LockTM
system for pull out protection of shank tools, which
is a unique innovation of the company. The system’sGrooves in the tool shankSpecial drive keys in the chuck

Developed by German manufacturer
HAIMER, the Safe-LockTM system’s special
drive keys in the chuck and grooves in thetool shank prevent the milling cutter fromspinning during extreme machining. The
end result - greater cutting speeds andlonger tool life. OSG also provides shrink fit
holders and shrink fit devices compatible
with the Safe-LockTM system.

special drive keys in the chuck and grooves in the tool
shank prevent the milling cutter from spinning during
extreme machining to enable greater cutting speeds,
longer tool life and a safer machining environment.
“Although it is rare for a cutter to completely come off
during the machining of aluminum, the tool has slipped
at the corner during roughing,” said Eto.
“If slippage occurs during high-speed milling at 120
kW, the tool will chip. In the worst case scenario, thecutter will eventually become a round bar that cannot
perform any cutting and will collide with the workpiece,
which damages the spindle,” Eto explains. “This scenario
must be avoided at all costs, so we decided to install the
Safe-LockTM system.”
Furthermore, in order to suppress variations in theoverall tooling, HAIMER’s Tool Dynamic Comfort
Plus balancing machine is used to better control the
influence of centrifugal force under high rotation.
In order to manage preset errors, an automatic tool
measuring device is also deployed.
MHI’s new 5-axis horizontal machining center andthe corresponding equipment are installed at the Eba

Factory, where the 777X fuselage assembly plant islocated, in order to streamline the production process.
The project is being tackled by a team of young
technicians including Takanori Terasako, who are
enthusiastic about the opportunity to manufacture
aircraft parts using a new machining center, toolingsystem, and machining method. Since the schedule
for the new model development project is relatively
tight, lead engineers Eto and Unno from the Oe Factoryjoined the Eba project team at the time of startup. In
addition, Kentaro Masutani, a technician who is highly
experienced in machining large-scale machine parts
also participated as a supporting member from steelplant builder Primetals Technologies Japan Co., Ltd., asubsidiary of MHI.
“In the simulation, we set the cutting conditions
while also looking at the load on the bearings,” said
Eto. “In order to reduce the difference between theactual cutting and the simulation, high quality ofthe tool cutting edge, preset accuracy, and vibration
characteristics from the machine to the tool tip mustbe achieved,” Eto elaborates. So, the machine operators
were requested to realize very high accuracy in preset
operations.
SHAPE IT   Feature8

A section of MHI’s Eba Factory in Hiroshima that is currently designated for the production of the Boeing passenger aircraft 777X.

“Unlike before, it was difficult at first to satisfy the automaticallymeasured balance value and preset accuracy,” said Terasako. “However,
OSG’s AERO end mill has a high shank accuracy and we are able topreset relatively smoothly.”“In terms of cutting conditions, steel and aluminum are very
different,” said Masutani. “But I think that the technology introducedfor high-speed machining of aluminum can be applied to themachining of steel as well.”According to Unno, various problems arose during startup due tothe adoption of a new machining process. “But thanks to the stableperformance of the tooling, we were able to concentrate resources totrouble-shoot quickly,” said Unno.
Eto adds that the AERO end mill is able to operate smoothly underidentical conditions set during the simulation. “It is the stable qualityof the tooling side that makes this replication possible,” said Eto.
Although it was the first time for MHI to introduce a 33,000 min-1
spindle speed machine, its project team was able to overcome
various challenges. Despite having to create a newly designed partusing a new machining method, the team successfully completed
the setup of the equipment in a short period of three weeks tocomplete the first product.
With the perfect combination of machine tool, cutter and holder,stable slotting and pocketing at a speed of 33,000 min-1 and a feed
rate of 25,000 mm/min can be achieved.
9

SHAPE IT   Feature

Inside a section of MHI’s Eba Factory in Hiroshimathat is currently designated for the production of the
Boeing passenger aircraft 777X. MHI is responsible
for producing sections of the rear and tail fuselage
as well as the passenger entry doors of the Boeing
passenger aircraft 777X.

From left, Jun Eto and Hirokazu Unno, MHI lead engineers from the Manufacturing Engineering Department’s Tool Design Team. Since theschedule for the new model development of the 777X project was relatively tight, the pair joined the Eba project team in Hiroshima at thetime of startup to provide support.

With the OSG AERO end mill, metal removal rate reaches
6,200 cc/min at its maximum. Machining time is reduced
by approximately 75 percent versus conventional
machines.
MHI is currently producing several dozens of thesealuminum parts every month. The cutter and tool holder
from OSG and HAIMER are continuing to demonstrateconsistent performance. Also, machine spindles ingeneral are replaced in roughly a year. In MHI’s case, its
machine spindle is still in good shape after more than
three years and can be used under identical cutting
condition.
Osamu Nakano, who is in charge of introducing andmanaging milling machines and their associatedequipment adds that “compared to previous machines,
I am surprised that there are few failures around thespindle and made me recognize the importance oftooling quality.”
Unno joins in and adds that by selecting the most
optimum tool and tool holder, the required machining
time has been reduced to 25 percent versus
conventional method, and the life of the machine
spindle has more than tripled. “In addition, by utilizing
the Safe-LockTM system, work defects caused by tool pullout can be prevented and results have demonstrated its
effectiveness,” said Unno.

According to Eto, mass production of the 777X
began a couple of years ago and production rates
are planned to increase. It is necessary to further
enhance machining efficiency. At MHI, the company
always strives to channel new ideas into solutions
that move the world forward. “We are not satisfied
with the status quo as growth does not stop,” said Eto.
“We will continue to gather information from all over
the world and pursue the latest technology to move
aircraft manufacturing forward.”

Scan to learn more about MHI.

Scan to learn more about
OSG’s AERO end mill series.

Scan to learn more about the
OSG-HAIMER Safe-LockTM system andcorresponding products.

SHAPE IT   Feature 10

ADO-40D and 50D

Coolant-Through Carbide
Ultra-efficiency in deep-hole drilling applications
Takahiro Yamamoto
OSG Corporation Applications Engineer (Drill Development Division)
For many years, gun drills and HSS long
drills have been the tooling of choicefor deep-hole applications. For drilling
depth of 30xD or less, carbide twist drills
capable of high-efficiency performance
have become more and more widespreadin recent times. However, for deephole applications exceeding 30xD, it isstill a great challenge for carbide twist
drills to achieve stable high-efficiency
performance. Thus, gun drills continue tobe commonly chosen for ultra-deep-holescenarios.
OSG Corporation is pleased to introduce
one of its latest drilling innovations fordeep-hole applications – the ADO-40D
and 50D coolant-through carbide long
drills – engineered for ultra-efficiency
and superior stability with performanceequivalent to drilling 30xD or lower
depth.

11 SHAPE IT   Technical InsightFeatures of ADO-40D and 50D
There are three key features of the ADO-40D and 50D that
contribute to high-efficiency and stable machining ofdeep holes exceeding 30xD. The most important feature is
its newly developed R gash geometry.

ADO-40D
ADO-50D

Long Drills
ADO-40D & 50D. The ADO
coolant-through carbide long
drill series is one of OSG’slatest drilling innovations forultra-efficiency in deep-holeapplications.

Although conventional carbide twist drills are capableof producing finely divided chips, when machining
steel materials such as carbon steel, alloy steel
and stainless steel, elongation of chips can easily
occur. The unstable chip shape interferes with chip
evacuation, which is especially problematic in deephole drilling, and may lead to sudden tool breakage.
The ADO’s newly developed R gash geometry
expands the chip room at the center of the tool
where chips are difficult to be discharged. With the
optimized R shape to guide the direction of chip
flow, chips can be evacuated smoothly. Moreover,with this new feature, the curling of chips iscontrolled, and the consistency of chip shape
has significantly improved to allow superior
chip separation versus the conventional
design. In addition, the cutting force (thrust
resistance) is reduced by approximately
30 percent compared to the conventional
design, thereby enabling the suppression ofmachining vibration in high-feed machining
and improves straightness during drilling.

The second key feature of the ADO long drill is its new
flute specification that enables smooth evacuation of
the compact chips created by the R gash geometry,
while maintaining high tool rigidity of the long tool
body necessary for 40xD and 50xD applications. Chip
evacuation capability has been greatly amplified byexpanding the width of the flute, which functions
as chip room. A 25-degree helical flute geometry isapplied to enhance rigidity without interfering chip
evacuation capability.
Last but not least, just as important as the previous
two key features is the adoption of OSG’s original
EgiAs coating for high durability. The EgiAs coatingis consist of overlapping nano-periodical layers andwear-resistance layers, engineered to suppress the
propagation of cracks that are likely to occur during
drilling. The wear-resistance layer is composed ofmultiple hard layers; while the nano-periodical is acombination of hard and soft layers. With a mixtureof hard and soft layers, internal stress can be relieved,
allowing the EgiAs coating to achieve both high wear
resistance and extreme toughness to ensure stable
and consistent tool life under aggressive cutting
conditions.

Figure 1. Newly developed R gash geometry.
The newly developed R gash geometry
enables a cutting force reduction of 30 percent
or more compared to the conventional design
with exceptional chip shape stability.

SHAPE IT   Technical Insight 12

Cutting Data
As mentioned previously, the most notable advantagesof the ADO long drill are its consistent chip separation
ability, low cutting resistance, and capability to achieve afine balance between tool rigidity and trouble-free chip
evacuation regardless of the long cutting depth to allow
stable and efficiency processing.

1. Consistent Chip Separation Ability
Figure 2. Chip shapes in alloy steel SCM420H, which is highly viscous among steel materials.

f = 0.20 mm/rev

Benefit of R Gash Geometry
Work Material

SCM420H

Tool DiameterØ 5 mmHole Depth

250 mm (blind)Cutting Speed

60 m/minFeed

0.20 – 0.25 mm/rev

Processing Method

Non-step

Coolant

Water-soluble(dilution concentration 5%)

Coolant Pressure

7 MPa

MachineMultifunction Lathe

Pilot Hole Diameter / DepthØ 5 / 25 mm

Pilot Hole
Processing Condition

Vc = 60 m/min
f = 0.15 mm/rev

Competitor

ADO-50D

f = 0.25 mm/rev

Competitor

As depicted in figure 2, the competitor carbide twist drill
is unable to separate the chips effectively and ended up
with elongated chips. The ADO-50D, on the other hand,demonstrates finely divided chips that are consistent in

ADO-50D

shape. The stability of cutting chips is one of the mostimportant factors for achieving stable machining in deephole applications. As will be depicted later on in the article,
this factor is the key to stable and extremely long tool life.

2. Low Resistance Processing
Figure 3. Cutting force resistance comparison when machining SCM440.
［ N ］640
Competitor (40D)

ADO-40D

Thrust480

Size：φ 3

320

Work Material：SCM440 (82〜 90 HRB)
Cutting Speed：80 m/min（8,493 min -1）

160

0

Feed： 1,188 mm/min（0.14 mm/rev）024Time［ S ］

6

As shown in figure 3, the thrust resistance generated by
the ADO-40D has been reduced by approximately 30
percent compared to the competitor drill (conventional

13 SHAPE IT   Technical Insight

8

10

design). The recorded waveform is calm and consistent,
contributed by the ADO-40D’s smooth chip evacuation
capability for stable performance.

3. High Tool Rigidity with Excellent Chip Evacuation for Achieving Stable Machining
For long drill lengths such as 30xD, 40xD and 50xD,
the tool rigidity is reduced by nature due to the longoverhang length. By increasing the bottom flute diameteror by reducing the helix angle can enhance tool rigidity.
However, since the machining depth is deep, the path
required for chip discharge is also lengthy. If too muchemphasis is placed on the tool rigidity, chips cannot

be evacuated smoothly. To resolve this challenge, theADO-40D and 50D carbide long drills have employed a
25-degree helix angle versus the 30-degree helix angle
commonly found in coolant-through carbide drills. This
design ensures tool rigidity without impairing chip
evacuation.

Figure 4. Helix angle’s effect on machining

Benefit of 25° Helix Angle

Benefit of 25° Helix Angle

Work Material

SCM440 (82-90 HRB)

Coolant

MQL (50 cc/h)

Tool DiameterØ 6 mmCoolant Pressure

0.8 MPa

Hole Depth

300 mm (blind)

MachineHorizontal Machining Center

Cutting Speed

60 m/min

Pilot Hole Diameter / DepthØ 6 / 30 mm

Feed

0.30 mm/rev

Pilot Hole
Processing Condition

Vc = 60 m/min
f = 0.12 mm/rev

Processing Method

Non-step

As depicted in figure 4, vibration due to insufficient
tool rigidity is observed during machining with theconventional 30-degree helix angle. While the 20-degree

helix angle configuration has difficulty discharging
cutting chips. The 25-degree helix angle demonstrates
excellent stability and smooth chip evacuation.

SHAPE IT   Technical Insight 14

With the previously mentioned key features of the ADO
carbide long drill and the effect of OSG’s newly developed
EgiAs coating, long tool life and stable machining is
made possible in deep-hole applications. Figures 5 and 6

highlight the superior performance of the ADO long drills
that far surpass gun drills and other competitor products.

Figure 5. Performance versus gun drill (Hole size: dia.8 mm)

Roller Shaft Processing in SCM440 (performance comparison against gun drill + twist drill)
Process
Conventional
MethodCompetitor(50D Type)

ADO-50D

ItemFirst Step

Second Step

Third Step

Tool

Competitor carbide drill(5D type)

Competitor carbide long drill(30D type)

Competitor
gun drill

Hole Depth

40 mm

215 mm

391 mm

Cutting Condition

Vc = 60 m/min,
f = 0.16 mm/rev

Vc = 50 m/min,
f = 0.12 mm/rev

Vc = 60 m/min,
f = 0.06 mm/rev

Tool Life

1,250 holes
Wear and replacement

200 holes (35 m)
Wear and replacement

150 holes (26 m)

Tool

Competitor carbide drill(5D type)

Competitor carbide long drill(50D type)

Hole Depth

40 mm

391 mm

Cutting Condition

Vc = 60 m/min,
f = 0.16 mm/rev

Vc = 70 m/min,
f = 0.15 mm/rev

Tool Life

1,250 holes
Wear and replacement

Less than 60 holes (< 21 m)
Breakage and clogging of chips

Hole Depth

40 mm

391 mm

Cutting Condition

Vc = 70 m/min,
f = 0.24 mm/rev

Vc = 62.8 m/min,
f = 0.3 mm/rev (3.7% x D)

Versus Conventional(Efficiency)

175%

Vs. competitor 30D: 314%
Vs. gun drill: 523%

Tool Life

1,750 holes
Wear and replacement

256 holes (90 m)
Can continue to be used

Versus Conventional(Tool Life)140%

Vs. competitor 30D: 257%
Vs. gun drill: 346%

Figure 5 introduces an example of using the ADO-50D
to reduce the number of steps required for deep-hole
drilling to improve higher processing efficiency while
extending tool life.
Conventionally, deep-hole applications require the useof three tools – pilot hole drill, carbide twist drill (up to27xD) and gun drill. However, in the cutting example
illustrated in figure 5, the process is carried out in two
steps, where only two tools – pilot hole drill and carbide
long drill (50xD) are used to reduce the number ofprocesses, increase efficiency and extend tool life. With

15 SHAPE IT   Technical Insight

Cutting edge condition of
ADO-50D after drilling 256 holes

Unstable
processing;unable toreduce tool
used andsteps

Reduction intool usedand steps

the competitor long drill, machining is highly unstable
and tool life is short. Thus, it is not possible to perform theoperation in two steps. By employing the ADO-50D, on
the other hand, significant processing time reduction andlong tool life can be achieved. The long drilling process
after the pilot hole can be completed with a single tool.
Moreover, tool life is estimated to be 1.3 times longer withmore than 2.5 times the drilling distance being machined.
In this cutting trial, the ADO-50D is able to perform at
more than 3 times the processing efficiency stably versus
the conventional method.

Figure 6. Performance versus the competitor
Transmission Shaft Processing(performance vs. competitor twist drill)Tool

ADO-50D Ø 5 mm

Work Material

SCM420H

Processing Method

Non-step

Cutting Speed

50 - 60 m/min

Feed

0.2 – 0.3 mm/rev

Hole Depth

250 mm (blind)

Coolant

Water-soluble(dilution concentration 10%)

Coolant Pressure

7 MPa

MachineHorizontal Machining Center(BT40)

Pilot Hole Diameter / DepthØ 5 / 25 mm

Pilot Hole
Processing Condition

Vc = 60 m/min
f = 0.15 mm/rev

Tool Life Comparison
ADO-50(Vc = 60 m/min,
f = 0.3 mm/rev)

Can continueCompetitor
Carbide Twist Drill(Vc = 50 m/min,
f = 0.2 mm/rev)

Breakage

ADO-50(Vc = 50 m/min,
f = 0.2 mm/rev)

Can continue

0

100

200

300

400

Number of processed holes (Holes)

Vc = 50 m/min, f = 0.2 mm/rev,
cutting edge wear condition
after drilling 322 holes

Vc = 60 m/min, f = 0.3 mm/rev,
cutting edge wear condition
after drilling 322 holes

As depicted in figure 6, the competitor carbide twist drill
encountered sudden breakage due to unstable chip shapeand chip evacuation, which can commonly occur at 100 holesor less. The ADO-50D, on the other hand, is able to machine
under identical cutting condition as the competitor, but with
1.8 times the machining efficiency and more than 3 times thetool life consistently.
The ADO-40D and 50D are able to demonstrate their superior
capability to eliminate machining troubles such as abrupt tool
breakage, short tool life, long processing time and unstableperformance commonly found in deep-hole applications.
The newly developed R gash geometry applied in the ADO
long drill is also used in OSG’s ADO-TRS 3-flute carbide drill for

ultra-machining efficiency and stability in steel applications.
In the future, OSG will look to apply this unique specification
to other products and evolve the company’s A-Drill series tobetter meet today’s demand of higher stability, efficiency,
longer tool life, and greater precision machining.
For manufacturers who are struggling with deep-hole drilling,
look to the ADO-40D and 50D to experience ultra-processing
efficiency and stability.
The ADO-40D is available from diameter 3 mm up to 10
mm. The ADO-50D is available from diameter 3 mm up to
8 mm. Custom sizes are also available upon request. The
manufacturable range of special sizes is indicated in figure 7.

Figure 7. Manufacturable range of special sizes

Scan for details

SHAPE IT   Technical Insight 16

From left to right, OSG Sulamericana Product Designer James Reis, ZF Engineer Guilherme Gonçalves, ZF Engineer Éldio Pinto, ZF Tool Presset
Matheus Ribeiro and OSG Sulamericana Sales Technician Bruno Dias pose for a photograph at ZF’s manufacturing plant in Limeira, São Paulo, Brazil.

Tailored Solution
OSG custom carbide tap eliminates chip evacuation issues in automotive pipe
production
Marcela Rattin Bombini
OSG Sulamericana
Founded in August 1958, ZF do Brasil Ltda. is an
automotive company, with one of the eight facilities
located in the city of Limeira, São Paulo, Brazil, with anestimate plant area of 50,000-square-meter. ZF do Brasil
is a part of the ZF Group, which was established in 1915.
Headquartered in Friedrichshafen, Baden-Württemberg,
Germany, the ZF Group is a global technology company
that supplies systems for passenger cars, commercial
vehicles and industrial technology, enabling the next
generation of mobility. As of today, the ZF Group isavailable in approximately 230 locations in 40 countries.
Recently, ZF was looking to improve tool performanceon its automotive pipe production, which is used in car
steering mechanism for the automotive segment. Madeof SAE 1045 forged steel, ZF produces approximately
900,000 pieces of pipes per year, and it is one of thelargest productions of the company. ZF has been
manufacturing this part for about four years. Eight

17 SHAPE IT   Customer Reportpieces of pipes are produced per machine cycle. Eachpart requires vertical threading of one blind hole using
an M14 tap. The hole is 46 mm in length, 38 mm indepth, and with a tap tolerance of 7H. The thread finish
should be polished and without burrs.

OSG Sulamericana Sales Technician Bruno Dias inspects a finishedthread made by OSG’s custom carbide tap at ZF’s manufacturing
plant in Limeira, São Paulo, Brazil.

1

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1. From left, OSG Sulamericana Product Designer James Reis, ZF Engineer Guilherme Gonçalves, ZF Engineer Éldio Pinto and OSG
Sulamericana Sales Technician Bruno Dias, inspect OSG’s custom carbide tap.
2. A custom carbide tap M14 x 1.5 7HX with AlTiN coating was developed specifically for ZF’s automotive pipe production to eliminate
tapping issues.
3. Made of SAE 1045 forged steel, ZF produces approximately 900,000 pieces of automotive pipes per year, and it is one of the largest
productions of the company.
4. In addition to standard items, OSG also offers custom tooling as well as modification and coating services to help manufacturers maximize
productivity and quality.

ZF was originally using a carbide tap M14 for theapplication. However, the company was experiencing
great difficulty with irregular chip formation, bird nesting,and elongated chips that cause chipping of the fillets.
Furthermore, with cutting chips clogged up in thebottom of the hole unable to be evacuated, issues such as
chipping and tool breakage were also a great headache
for the company. OSG Sulamericana was an existingtooling supplier for ZF in other applications. When theopportunity arose to compete within this process, OSG
entered and won the order with superior result.
Upon a detail evaluation of the manufacturing process,
OSG Sulamericana Sales Technician Bruno Dias proposeda custom carbide tap M14 x 1.5 7HX with AlTiN coating
developed specifically for the application. OSG’s custom
carbide tap was put into a Doosan MV3016LS verticalmachining center, running at a cutting speed of 30
m/min with soluble oil. ZF’s previous tooling choice wasable to complete 1,200 pieces. OSG’s custom tool, on theother hand, was able to complete 2,880 pieces, whichmore than doubled the efficiency. Immediately, ZF was

ZF’s machine operator prepares for the machining of automotive
pipes using a Doosan MV3016LS vertical machining center.

able to obtain an improvement in the threading process,a gain in tool life, as well as setup time.
“We cannot be more pleased with OSG’s service,” said ZF
Engineer Guilherme Gonçalves. “Bruno is always present
when help is needed. ZF looks for reliable partners to
help during time of troubles, and OSG is always there,
which contributes to a long-lasting partnership.”

SHAPE IT   Customer Report 18

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

High Speed Machining
The perfect combination of cutting tool, tool holder and machine tool takes moldmanufacturer to a new level of productivity
Steve Lauman
OSG USAFor the past 20 years, Lifetime Products Incorporated’s
mold shop has been producing aluminum blow molds
to support the company’s production of plastic tables,
chairs, coolers, kayaks, outdoor sheds, and much more.
Lifetime first started its legacy in the sporting goods
industry in 1986, introducing a breakthrough basketballsystem that can be adjusted in seconds. It was the firstsystem that allows basketball hoop homeowners toeasily raise and lower the height quickly. Since then,Lifetime has become the world’s largest manufacturer ofresidential basketball hoops as well as folding tables andchairs, selling products in 58 countries around the globe.
Today, the company has grown from 15 employees in apartial warehouse to over 1,500 employees around theworld, serving the sporting goods, folding furniture,lawns and garden, playground and the watersports
markets.
Lifetime’s global business and manufacturing
headquarters is located in Clearfield, Utah, USA.
Lifetime’s mold division, which was establishedin 1999, currently employs 23 staff and has an

19 SHAPE IT   Customer Report

estimate production area of 16,000-square-feet. As
an organization that is committed to innovation andquality, Lifetime is constantly looking for ways toimprove their manufacturing process.
For some time, Lifetime has been searching for new
solutions to enhance efficiency in their mold production
primarily made of aluminum materials such as 6061,
7075 and QC10. In terms of production volume, Lifetimeon average produces 20 to 30 molds per year. Lifetime
Mold Engineer Dennis Norman and Lifetime Head CNC
Programmer Randy Macari are well versed on highspeed machining and how it can help them attain muchhigher productivity. They also understood the required
three essential components in order to maximize thebenefit of high speed machining – high performance
tooling capable of running high speed machining
programs, precision holders to secure tool engagement
at high rpms, and a machine tool with features suchas look ahead software and the ability to run at highspeeds.

2

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1. Combined with Lifetime’s new Mazak vertical machining center, OSG’s 3/8” 3-flute Blizzard end mill is able to reach its full potential, withparameters as high as 15,000 rpm and 220 ipm to generate unparalleled results in productivity.
2. Lifetime’s mold production is primarily made of aluminum materials such as 6061, 7075 and QC10.
3. For the past 20 years, Lifetime Products Incorporated’s mold shop has been producing aluminum blow molds to support the company’s
production of plastic tables, chairs, coolers, kayaks, outdoor sheds, and much more.

The first requirement of high-performance tooling
was met when Lifetime began utilizing OSG end mills.
Lifetime’s previous tooling choice was a 3/8” 3-flute end
mill that was used at 6,000 rpm and 60 ipm. The second
requirement was met with OSG’s HY-PRO shrink fit
holder and shrink fit technology. OSG’s balanced holder
gave Lifetime the ability to mill in excess of 20,000rpm. The fulfillment of the first two requirements has
greatly improved tool life and performance at Lifetime.
However, further progress was held back because
Lifetime’s older machine tools are incapable of runninghigh speed machining programs. It all changed when
this past year, a new Mazak FJV-60/120 vertical millarrived with look ahead controls designed for highspeed machining along with a high-pressure coolant
through spindle. With the equipment update, Lifetime
is now able to fully leverage OSG’s Exocarb Aero Blizzard
high performance carbide end mill.
The Exocarb Aero Blizzard series is a part of the OSG
premium line of carbide high performance end mills
specifically designed for aluminum and copper alloys.
The series’ special end cut gashing and offset teeth
permit large depths of cut and maximum feed per
tooth. Made with polished flutes to enhance tool lifeand reduce built up edges, the Blizzard end mill series isengineered to yield high metal removal rates in roughing
applications while providing a superior finishing.
Combined with the new Mazak vertical machining
center, OSG’s 3/8” 3-flute Blizzard end mill is now able toreach its full potential, with parameters as high as 15,000rpm and 220 ipm to generate unparalleled results in
productivity. These improvements across all the different
milling operations at Lifetime have created an averageof 25 percent cycle time reduction. A typical mold is
now machined and built in less than 12 weeks, downfrom an average of 16 weeks. In addition to increased
speeds and metal removal rates, Lifetime also saw much
improved surface finish, which lowered labor costs by
reducing the amount of labor time needed to polishthe cavity components of each mold. The combinationof a quality tool with precision tool holder engages theworkpiece in a more rigid and stable environment, thus
resulting in a better surface finish. The overall polishingtime was reduced by more than 75 percent. Mold
polishing in general added 40 hours to the mold build
time, which has now been reduced to eight hours.
“OSG’s Blizzard end mill’s performance helped exceed our
objectives needed to deliver our molds faster and better,”said Lifetime Products CNC Programmer Randy Macari.
High productivity can only be achieved with the perfectcombination of cutting tool, tool holder and machinetool. By constantly improving, innovating and leveraging
the latest manufacturing technologies, Lifetime willcontinue its journey in creating affordable and lastingproducts for consumers and their families.

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

SHAPE IT   Customer Report 20

AT-2
Helical Drilling and Threading Combo Tool for High-Hardness Steels

OSG’s latest AT-2 carbide thread mill isdeveloped specifically to combine the drillingof a pilot hole and threading into a single
procedure even in difficult-to-machinematerials such as high-hardness steel. The
AT-2 features a unique high strength cuttingedge shape to control the bending of tool. It isengineered with a left-hand cut configuration
for climb milling to prolong tool life by
reducing tool deflection and the generationof heat. Roughing teeth are also added to

distribute tool load. Furthermore,
the AT-2 is coated with OSG’soriginal DUROREY coating
to suppress chipping in
high-hardness steel
applications.

AM-EBT and AM-CRE
Carbide End Mills for Additive Manufacturing Applications

The AM-EBT ball type carbide end mill featuresa robust 3-dimensional negative geometry
optimized for large depth of cut. The AM-CRE
radius type carbide end mill is available in
6-flute or 8-flute configuration. The AM-EBT
and AM-CRE end mills are recommended

21 SHAPE IT   Product Pickup

for hardened steel, pre-hardened steel,stainless steel, heat-resistantalloy additive manufacturing
applications and built-up
welding parts.

Phoenix PSTW
6-Corner Shoulder Milling Cutter

The OSG Phoenix PSTW 6-corner shoulder
milling cutter is designed for high efficiency
heaving milling. The PSTW series is engineered
to effectively process long overhang length

applications with strong chattering
resistance with its high rigidity
and positive rake angle
geometry.

AD and ADO
Solid and Coolant-Through Carbide Drill Series

The AD and ADO are OSG’s next generationhigh performance solid and coolant-throughcarbide drill series designed for every drilling
application. Low thrust, enhanced durability
and stable drilling is made possible with the
adoption of a unique point form. With theaddition of OSG’s original EgiAs coating, highwear resistance can be achieved to further
prolong tool life. The AD solid carbide drill isavailable in 2xD and 4xD. The ADO coolantthrough carbide drill is available from 3xD up
to 50xD.

SHAPE IT   Product Pickup 22

OSG Corporation launches Web Showroom tomanufacturers in a new exhibition style
OSG Corporation has recently launched a
new online exhibition website – the OSG Web
Showroom. Many exhibitions have been canceledor postponed due to the spread of the coronavirus.
Moreover, due to the postponement of the Tokyo
Olympics, it has become a challenge
to secure venues for exhibitions
domestically. As sales and services
must continue to accommodate newattitudes and behaviors in the era of
COVID-19, the company has looked
beyond tradition exhibitions and opted
for a digital experience that is not tied
to time or place.

Incorporation of various functions
that emphasize customer communication
OSG considers an exhibition to be a place forcommunication with its customers. It is the corevalue of exhibiting at a trade show that the company
interacts with customers who visit the booth, rather
than unilaterally promoting products. The new OSG
Web Showroom is no different. OSG offers a live chatfeature (currently available in Japanese only) that allows
its representatives to communicate with customers
seamlessly. Visitors can discuss about tools and

23 SHAPE IT   OSG News

machining with ease just like they would physically at an
exhibition booth. Live chat support is handled by OSG’stechnical staff who are experts in the field. In addition
to tool selection and calculation of cutting conditions,
OSG also has a system in place to respond to a wide
range of inquiries regarding machining methods andmachine setup. With the addition of the chatbot feature,
information such as product brochures and application
videos can be easily and quickly accessed.

connect with

Although the global outbreak of COVID-19 presents
a significant challenge for physical interaction, it isalso driving organizations to reinvent and evolve
through the use of digital technology. With the new
OSG Web Showroom platform, OSG will strive to meetcustomer expectations with even greater creativity andinnovation.

Access the OSG
Web Showroom

SHAPE IT   OSG News 24

OSG Around the World
Employee Interview with

Jason Kennedy
Tell us about your work and experience at OSG.
From the start of my career, I have always been involvedin the manufacturing industry. I began my machining
apprenticeship in the United Kingdom two days
after my 16th birthday in 1991. Upon completing myapprenticeship early, just under three years, I started
working in a couple of machining cells, manufacturing
various components for steam turbine generators. In
2000, I had the opportunity to manufacture racing
engines for various motorsports, such as Formula 1,
World Rally Championship, Grand Prix motorcycle
racing, IndyCar, etc. In 2005, I changed employers where
I held the position of an electromechanical maintenanceengineer. In 2006, my family made a life-changing
decision and we decided to immigrate to Canada. We
immigrated directly to Calgary, Alberta where I worked
in the oil and gas sector for four years, before joining
OSG Canada in August 2010. My original position
was sales engineer for the provinces of Alberta andSaskatchewan. In 2014, I was promoted to my current
position as western regional manager.

Jason Kennedy
Location: Canada
Position: Western Regional Manager
Joined OSG: 2010
Motto: “Opportunities don’t happen. You create them.”

Tell us about your daily routine.
Being in sales, I cannot sit back and wait for the sales
to come to me. I have to plan and strategize in order togrow sales for my territory. One of the most interesting
challenges for my work is how my workday varies fromday to day. Depending on the day of the week, I could
be stepping on a plane at 6 a.m., joining the highway
for a several hour drive, meeting with a customer
to discuss an application, or my favorite part of all –testing an OSG tool on the customer spindle.

Kennedy’s family immigrated to Canada from the United Kingdom
in 2006 and recently became fully fledged Canadian citizens.

25 SHAPE IT   Meet OSG

What is most challenging about your work?
Like a lot of careers, time management can be one of
the main challenges, and this is no different for me. OSG
has many customers – both distributors and end users.
I sometimes find it a challenge to meet with everyone
locally, while also communicating with customers who
are reaching out to me from other cities in my territory.
Although managing this juggling act can be time
consuming, it is also very rewarding when things fall
into place.

What is unique about OSG Canada?
OSG Canada has terrific teamwork. Our employees
are our strengths, who are always providing teams
out in the field with exceptional support behind thescenes. Having a reliable network of support enables
us to have the confidence to provide the best possible
products and services to our clients in Canada.
What is your favorite OSG tool?
My favorite OSG tool is the AE-VML long flute carbide
end mill, which is a part of the A Brand AE-VM antivibration carbide end mill series. In my main territory,
there is a lot of solid carbide end mill applications. In
the past, I have found that our competitors are able
to offer some very competitive products. However,
OSG’s A Brand end mills are very well received andhave demonstrated consistent positive results. Whenrunning the AE-VML end mill in particular, this tool isable to stand head and shoulders above other similarcompetitive products in the market.

3

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1. During time off work, Kennedy enjoys mountain biking on the trails.
2. A photograph of a moose calf taken from the Fish Creek Provincial
Park in the southern part of Calgary, Alberta, Canada. According toKennedy, wildlife sometimes would wander into the city from themountains.
3. Kennedy watches his 13-year-old son Bill plays competitive ice
hockey.
4. A photograph from the Johnston Canyon in Banff National Park.
There are several hiking trails that are open all year round.
The AE-VML long flute carbide end mill is a part of the
AE-VM anti-vibration carbide end mill series designed
to attain an all new level of milling efficiency coupledwith superb finish quality suitable for a variety of milling
applications. High-speed side milling is made possibleby the AE-VML’s large thick core design. Its unique flute
form with high tool rigidity and excellent chip evacuation
properties enables stable milling performance andthe suppression of burrs. With the addition of OSG’soriginal DUARISE coating, tool life can be enhanced by its
excellent lubricity, superior friction-resistance and highoxidation temperature qualities.

Kennedy’s family enjoys spending time outdoor and would often
camp near the Canadian Rockies.

How do you spend time on your day off?
I have two children, Keira, who is 15 years old, andWilliam, who also goes by Bill, is 13 years old. Bill plays
competitive ice hockey and basketball. As any sports
parent knows, this can be a full-time commitment, withthe team members being like a temporary family for the
sports season.
I live in Calgary, Alberta, which is approximately 1-hour
east of the Canadian Rockies. So, my family always
tries to spend as much time outdoors as we can, allyear round. Whenever we get a chance, we will headout camping in the mountains. Canada is the home toa large population of wildlife, such as bears, cougars,
wolves, moose, etc. The close proximity is phenomenal.
At the same time, however, we have to be cautious andrespectful of the wildlife.
I also like to get away from the hustle and bustle of thecity and will head out on my own or with some friends
mountain biking on the trails. When the weather is nice,the trip will often end with a BBQ when we return to thevehicle.

SHAPE IT   Meet OSG 26