FEATURE:

SMALL PARTS MACHININGOSG GLOBAL TOOLING MAGAZINE I WINTER 2024

Enhancing productivity andtool life in small part production

TECHNICAL INSIGHTGLOBAL REPORTS

OSG NEWSEMPLOYEE INTERVIEW

A-XPF Highly Efficient andMulti-purpose Forming Tap

USA
China
MexicoBrazilCIMT 2023
OSG Active
Green Tapin Turkey

Toward the Realization of a Sustainable
Society – Creation of “Green Tap”
A Message from the President
OSG’s mission is to contribute to the world of
manufacturing. In addition, we have enteredan era in which it is essential to promote
Green Transformation (GX) toward realizing a“decarbonized society.” Even after the coronavirus
pandemic, times of uncertainty remain. The speedof change is not only rapid, but the fluctuations arealso substantial, triggering great impact and anxiety
in the world today. In order to overcome these
difficult times, it is OSG’s duty as an industry leader
to support innovation, research and development,
facilitate growth, and to strengthen collaboration
between industry groups. This includes a wide
range of agendas, such as providing education andtraining programs, building international networks,
and improving the regulatory environment. To
fulfill our responsibilities to future generations,active efforts are required to achieve a sustainable
society. It is crucial to work in unison with the global
environment, improve energy efficiency, as wellas to utilize our technical capabilities to promote
environmentally friendly product development andprocess improvements.
At EMO 2023, which was held in Hannover, Germany
from September 18 to 23, 2023, OSG announced
the development of “Green Tap,” a new revolutionary forming tap innovation that contributes to the realization ofa sustainable society, marking a new chapter in the history of taps. Green Tap is made by OSG’s new and original
manufacturing method. Green Tap can minimize the amount of electricity consumed during tap manufacturing compared
to conventional methods, reducing CO2 emissions per tap by approximately 50 percent. Choosing Green Tap will lead toa reduction in CO2 emissions related to thread processing. Selecting products manufactured with consideration for theenvironment contributes to reducing environmental impact. Additionally, opting for high-performance cutting tools will
help minimize power consumption and lessen waste.
Through Green Tap, manufacturers can contribute to the realization of a sustainable society. In the future, environmentallyfriendly products will become increasingly sought after. I am confident that Green Tap will be a major first step for OSG.
Moving forward, we will further strengthen our ESG management efforts and strive to become an essential player in the
global manufacturing industry.

Nobuaki Osawa
President & COO of OSG Corporation

1

SHAPE IT   ﻿CONTENTS Feature
SHAPE ITWINTER 2024

3 Small Parts Machining

Technical Insight
9 A-XPF Highly Efficient and Multi-purpose Forming Tap

Customer Report
13 Aim for Leaner and More Efficient Manufacturing
WXL high performance carbide ball end mill reduces cycle time by half and demonstrates eight times
the tool life in 416 stainless steel gun barrel production

15 The First Choice for Thread Milling
AT-1 thread mill enhances processing efficiency in hydraulic valve production

17 Guaranteed Performance
OSG rack dies extend tool life and maintain production stability in automotive high-volume parts withinvolute splines

19 Turbocharge Performance
A-SIGMA-SFT spiral fluted tap and SynchroMaster tap holder accelerate productivity with reliable
performance in carbon steel hub production

Product Pickup
21 AE-CPR-N DLC Coated Long Neck Corner Radius End Mill,PFDC Facemill Disc Cutter

22 ADO 3-flute Coolant-through Carbide Drill, AT-2 Carbide Thread Mill with
End-cutting Edge

OSG News
23 OSG Participates at CIMT 2023
24 Establishment of Special Subsidiary OSG Active
OSG Announces Development of “Green Tap”

Meet OSG
25 Employee Interview in Turkey

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: January 2024
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

OSG’s ADF carbide flat drill and a valve seat.

Small Parts Machining
ADO-MICRO coolant-through carbide drill and ADF flat drill enhance
productivity and tool life in small part production
Yoshi Saito
OSG Thai

The machining of small components is not new in the
manufacturing industry, but the trend for lighter weight
and further miniaturization continues to accelerate.
Industries such as automotive, aerospace, electronics
and medical require the machining of an array of small
parts.
In general, any workpiece that is less than 25.4 mm indiameter can be considered as small. Application with3

SHAPE IT   Featurea part diameter less than 0.5 mm can be classified as
micromachining. With reduced weight and material,
holes required to be drilled have also become smaller.
Tool breakage is a common concern in small partproduction, as the slightest variation can cause a tool tosnap. Due to tight tolerances, cutting tools used in themachining of miniature components require sharpness,high surface quality, accuracy and performance stability.

From left, Global-Thaixon Production Engineer Saranphat Liangsakun, Global-Thaixon Engineering Director Kazushige Ishizawa and OSG
Thai Sales Representative Tantip Luangthongsri pose for a photography at Global-Thaixon’s facility in Chachoengsao, Thailand.

With advanced grinding know-how, OSG offers aspectrum of tooling solutions to fulfill increasing needsof small and micromachining. OSG’s small diameterand micro tooling incorporate high precision shank,
optimum tool geometry, grade, and a wide varietyof coating options to enable stable and accurate
machining of small and micro parts.
Recently, a leading manufacturer of precision partsin Thailand was able to leverage some of OSG’s latest
drilling innovations in the production of high-pressure
pump part and automotive part to eliminate tool
breakage and stabilize machining.
Found in 1990, Global-Thaixon Precision Industry Co.,
Ltd. (Global-Thaixon) is a leading manufacturer ofprecision components for a wide variety of industries
worldwide, serving sectors such as automotive,
electronics, medical, and more. Employing 900 staff,
Global-Thaixon’s manufacturing plants are located in
Chachoengsao, Thailand, with an estimate production
floor space of 32,700-square-meter.

Global-Thaixon offers a complete range of machining
and turning capabilities, including close to 400 setsof CNC machines operating around the clock. The
company’s tooling and milling department are
equipped with advanced computerized production
control system, which enables high precision andefficient production of complex parts. Aside fromturning and milling, Global-Thaixon also has a variety ofstamping machines ranging from 25 tons to 160 tons
for making high precision progressive mold for metal
stamping parts with short lead time.
Recently, Global-Thaixon was experiencing tool
breakage and short tool life in its spool and valve seat
applications. Seeking to improve productivity, toolingcost and profits, Global-Thaixon reached out to OSG fortechnical support.

SHAPE IT   Feature4

Spool Application
Spool is a high-pressure pump part made of SCM415.
This part is currently at the prototype stage and the
production volume varies. One blind hole at a depth of
36 mm is required to be drilled per part. The accuracy ofhole diameter needs to be within +/- 0.05 mm. The parts
are machined using CNC lathes. Global-Thaixon was
originally using a competitor drill for the machining.
However, the holes were not straight, had poor holeroundness and concentricity. Upon a detail evaluationof the application, OSG Thai Sales Representative
Tantip Luangthongsri recommended OSG’s ADO-MICRO.
The ADO-MICRO is OSG’s first small diameter carbide
drill with oil holes designed for stable and highefficiency drilling in deep-hole applications. Poor
chip evacuation is a common complication in small
diameter deep-hole drilling. Micro sludges can be easily
accumulated around the outer periphery of the cutting
tool, which is a key cause of abrupt tool breakage. The
ADO-MICRO features a unique double margin geometry
with an extended flute and shortened end margin toenhance chip evacuation capability. In addition to theoutstanding chip ejection performance, the double
margin configuration supports the straightness stabilityof the tool and reduces rifle marks on the inner surfaceof holes. Furthermore, the ADO-MICRO features apair of large oil holes and employs a hollow shankdesign to allow large coolant flow volume for troublefree chip evacuation. The ADO-MICRO is coated with
OSG’s original IchAda coating that provides excellent
surface smoothness in conjunction with high abrasion
resistance and heat resistance to enable small diametertools to achieve long tool life. With the
ADO-MICRO’s unique tool geometry and IchAda
coating, non-step drilling is made possible even fordeep-hole applications, enabling high processing
efficiency.

OSG’s ADO-MICRO small diameter coolant-through carbide drill isused in the processing of Global-Thaixon’s high-pressure pump partmade of SCM415.

A 2 mm diameter ADO-MICRO-2D (EDP# 8732017) is
first used as a pilot drill, followed by a 2 mm diameter
ADO-MICRO-20D (EDP# 8732056) to complete the hole.
The ADO-MICRO 20 x D is used under identical cutting
condition as the initial competitor drill, at a cutting
speed of 4,500 rpm and a feed rate of 0.075 mm/rev.
Global-Thaixon’s in-house Thaixon Pump is also used
to enhance chip evacuation. With the previous toolingchoice, 2-step processing was required. By switching to
the ADO-MICRO, non-step drilling is made possible andan estimate of 4 seconds of machining time has beenshortened per workpiece.

Spool - a high-pressure pump partmade of SCM415.
Each part requires the drilling of one
blind hole at a depth of 36 mm.

5SHAPE IT   Feature

Valve Seat Application
Valve seat is a small precision automotive part madeof EXEO-CR20 (high-strength and corrosion-resistant
stainless steel). Global-Thaixon has been manufacturing
this part for about eight years and has an annual
production of approximately 160,800 pieces. Six blindholes at a depth of 0.4 mm are required to be processed
per part using a 0.32 mm diameter flat drill. The
accuracy of hole diameter needs to be within+/- 0.015 mm. The parts are machined using CNC lathes.
Global-Thaixon was originally using a competitor tooland experienced inconsistent tool life and poor holeposition accuracy.
After reviewing the cutting conditions, OSG Thai Sales
Representative Tantip Luangthongsri recommended
OSG’s ADF carbide flat drill with a customized 0.32 mm
diameter. The ADF was developed with an “all-purpose”
concept for superior versatility, reliability and quality
for flat-bottom holes. Machining a flat hole traditionallyrequired the use of an end mill and a drill. For theprocessing of thin plate shaft parts, the ADF enables
one-step drilling, thereby simplifying machining time
and tool management. The drill’s balanced point form
improves precision and minimizes the shifting of thehole position. Its sharp cutting edge results in low
cutting force to minimize burrs even in thin plates.
With a wide chip room geometry, trouble-free chip
evacuation can be achieved. Furthermore, with theaddition of OSG’s proprietary EgiAs coating, tool life canbe prolonged with excellent heat and wear resistance.
The ADF series is engineered for a wide variety ofdrilling applications including inclined surfaces, curved
surfaces, counterboring, eccentric holes, thin plates,etc. It is suitable for materials such as carbon steel, alloysteel, hardened steel, cast iron and stainless steel.

Global-Thaixon’s initial competitor tool was used
at a cutting speed of 20,000 rpm and a feed rate of
0.0050 mm/rev. Performance was unstable, generally
averaging between 250 to 600 parts per tool. OSG’s
0.32 mm diameter ADF-2D was tested under identicalcutting condition at a speed of 20,000 rpm and afeed of 0.0050 mm/rev. With the initial competitor
tooling, the machining accuracy was not stable. Tool
life also varied among the supplied lot, making tool
management a great challenge. The ADF-2D, on theother hand, enables highly stable machining. Tool
life averages around 1,500 pieces, which is more thandouble the previous tooling choice.
“After switching to OSG’s ADO-MICRO and ADF drills,
we are able to reduce downtime required for changing
cutting tools, increase tool life for reduced tooling cost,and encounter less interruptions in machining due tosignificant improvement in part quality and accuracy,”
said Global-Thaixon Production Engineer Saranphat
Liangsakun.
Global-Thaixon has close to 400 automatic lathes(sliding head lathes) and is actively testing newly
developed products with a focus on small diametertools recently proposed by OSG. By leveraging the latest
cutting tool technology, manufacturing processes andproduct quality are enhanced, which ultimately delivers
greater values to clients.
“As a company committed to quality and customer
satisfaction, we look forward to the continued
partnership with OSG,” said Global-Thaixon Engineering
Director Kazushige Ishizawa.

Valve Seat - a small precision automotive
part made of EXEO-CR20 (high-strength andcorrosion-resistant stainless steel).
Six blind holes at a depth of 0.4 mm are required
to be processed per part using a 0.32 mm diameterflat drill.

SHAPE IT   Feature

6

About Global-Thaixon
Found in 1990, Global-Thaixon Precision
Industry Co., Ltd. (Global-Thaixon) is a leading
manufacturer of precision components for awide variety of industries worldwide, serving
sectors such as automotive, electronics,
medical, and more. Employing 900 staff,
Global-Thaixon’s manufacturing plants
are located in Chachoengsao, Thailand,with an estimate production floor space of
32,700-square-meter.
Global-Thaixon offers a complete range ofmachining and turning capabilities, including
close to 400 sets of CNC machines operatingaround the clock. The company’s toolingand milling department are equipped withadvanced computerized production control
system, which enables high precision andefficient production of complex parts. Asidefrom turning and milling, Global-Thaixon also
has a variety of stamping machines ranging
from 25 tons to 160 tons for making highprecision progressive mold for metal stamping
parts with short lead time.

1

In addition to the production of precisioncomponents, Global-Thaixon also offers highperformance pump solution with its original
Thaixon Pump, which increases the pressure of
cutting oil to improve cutting chip evacuation,
thus prolonging the tool life of cutting tools.

2

7

SHAPE IT   Feature

3

4

1. Global-Thaixon’s manufacturing plants are located in Chachoengsao, Thailand,with an estimate production floor space of 32,700-square-meter.
2. Global-Thaixon offers a complete range of machining and turning capabilities,
including close to 400 sets of CNC machines operating around the clock.
3. From left, Global-Thaixon Production Engineer Saranphat Liangsakun and OSG
Thai Sales Representative Tantip Luangthongsri pose for a photography inside
Global-Thaixon’s manufacturing facility in Chachoengsao, Thailand.
4. OSG’s ADF carbide flat drill enables stable machining of valve seat – a small
precision automotive part made of EXEO-CR20 (high-strength and corrosionresistant stainless steel).

SHAPE IT   Feature

8

A-XPF
Staying Ahead of Change with the A-XPF Highly Efficient andMulti-purpose Forming Tap
Keita Ono
OSG Corporation Applications Engineer(Tap Development Division)

The rise of environmental concern isincreasing year by year. Along with
this, a demand for environmentallyfriendly cutting tools has also become
more prominent than ever before.
OSG’s latest A-XPF high-efficiency
and multi-purpose forming tap is a
product that can respond to today’s
evolving manufacturing needs.
Compared to conventional products,
the A-XPF enables higher processing
efficiency, which reduces machining
time. In addition, by achieving longer
tool life, the number of tool changes
required can be minimized. Moreover,by enabling stable and uninterrupted
machining, power consumption can be
reduced.

9

SHAPE IT   Technical InsightCommon Tapping Troubles

TOP 3 Tapping Troubles

No.1
No.2
No.3

Breakage and chipping

26%
17%
14%
43%

Table 1 summarizes common tapping trouble consultations
received at OSG’s customer service center. The number one
trouble is tool breakage and chipping (26 percent); ranked
at number two is dimensional error (17 percent); galling isranked at number three (14 percent). The top three troubles
combined account for 57 percent of the total.

Table 1. Top 3 tapping troubles (source: OSG TechnicalConsultation Division)

In all cases, the main cause of trouble is cutting chip
related. During tapping, cutting chips often can become
entangled with the tap as depicted in figure 1. If machining
is continued under this state of condition, the chips will
get caught and the tap will likely chip or break. In addition,
as illustrated in figure 2, galling may occur in the internal
thread.

Figure 1. Chip packing – anexample of cutting chip relatedtrouble.

Dimensional error
Galling
OthersFigure 2. An example ofgalling.

How to TroubleshootTo resolve chip troubles, OSG has developed the A-XPF forming tap that forms threads by plastic deformation of thework material. Therefore, no chips are generated during tapping. In other words, troubles caused by chips can becompletely eliminated by leveraging the A-XPF to enable uninterrupted machining and maximize productivity.

Features of A-XPF
The first feature of the A-XPF is the adoption of a special chamfer specification, which contributes to achieving low
thrust. The second feature is its special thread configuration. The rigidity of the tap is ensured by adopting a special
thread geometry and a new relief shape. The third feature is the adoption of the VI coating. About 30 years after thecompany’s V coating, OSG has developed a new special coating uniquely engineered for taps.

1. Special Chamfer Specification
With the A-XPF’s special chamfer specification, the ridges at the tip of the tap are less likely to chip compared tothe conventional style. With forming taps, when the tool enters the hole, chipping may occur on the ridge at the
tip of the chamfer portion of the tap. The chipped section may lead to further chipping of the entire tap. The A-XPF
incorporates a unique geometry that suppresses chipping during thrust. Figure 3 depicts a graph of the thrustmeasured during tapping. Compared to a conventional product, the A-XPF is able to reduce the thrust and theamplitude of the waveform. By stabilizing the thrust waveform, the tool can stably enter the workpiece.

Drill Hole Size

φ2.8×9 mm (Blind )Cutting Speed

Cutting Speed
Coolant

Water-soluble
Chlorine-free (5%)

Water-soluble
Chlorine-free (5%)

Coolant
MachineMachine15 m/min (1,591 min-1)

15 m/min (1,591 min-1)

Vertical Machining Center(BT30)

30

30

6 mm

6 mm

40

30

φ2.8×9 mm (Blind )Tapping Length

Tapping Length40

40

ThrustDrill Hole Size

40

Thrust

SCM440 (30 HRC)SCM440(30 HRC)

Conventional
Product
Conventional
Product
［N］
［N］

20

20
10

20

10

10

10
0

0

30

20

ThrustWork MaterialWork Material

A-XPF
A-XPF
［N］
［N］

Thrust0.5 2P
A-XPFA-XPF
M3 ×M3
0.5×2P

Tool

Tool

0.5

0.5

Vertical Machining Center(BT30)

1

1.5

Time (s)11.5Time (s)

0

2

2

0.5

0

1

0.5

1.5

Time (s)

1

2

1.5

2

Time (s)Figure 3. Comparison of thrust during machining

SHAPE IT   Technical Insight 10

2. Special Thread Configuration
When using a forming tap, the crest of the tap thread may suddenly disappear. In general, the relief shape of theforming tap tends to emphasize sharpness and is marginless. The more emphasis is placed on sharpness, the lower
the rigidity of the tap thread becomes. The A-XPF adopts a new relief shape to suppress sudden chipping of thecrest of the thread. Figure 4 illustrates a comparison of relief shape between a conventional product and the A-XPF.
In the new relief, the shape of the cutting edge has not been altered to maintain sharpness while the back side of
the thread has been thickened to ensure rigidity. The enhanced thickness is depicted in black on the right diagramin figure 4.

Back
Cutting
Edge

Back
Cutting
Edge

Cutting
Edge

Conventional

Cutting
Edge

A-XPF New Relief

Symmetrical Relief

Figure 4. Comparison of relief shape

3. New VI Coating
The A-XPF employs a new VI coating developed exclusively for taps. The
coating structure is a Cr-based composite multilayer film as illustrated
in figure 5. Compared to the conventional V coating, the VI coating has
improved hardness, oxidation initiation temperature, adhesion, wear
resistance, and many other superior properties as shown in figure 6.
Since the new VI coating can handle high-load machining, higher speed
range can be achieved in comparison to conventional products.

Lubricate Layer
Wear-resistant Layer
Toughness Layer
Base Metal

Figure 5. Structure of the new VI coating

Coating

Coating
Color

Coating Structure

Hardness(GPa)

Oxidation
Temperature(°C)

Adhesion
Strength

SurfaceRoughness

Wear
Resistance

Welding
ResistanceToughness

VI CoatingBlackCr-based Composite
Multilayer Film

45

1,100

◎

☆

◎

☆

◎

V CoatingBlue Gray

TiCN

35

400

○

☆

○

☆

◎

（ Fair ）○→◎→☆（ Best ）Figure 6. Properties of the new VI coating

Performance of the New VI Coating
Figure 7 illustrates the result of machining a work material in SCM440 (30 HRC) using a M6 x 1 A-XPF under highspeed. With the conventional V coating, wear progressed after 7,000 holes. With the new VI coating, on the other
hand, 11,000 to 12,000 holes can be machined. The new VI coating has demonstrated over 30 percent longer life
than the V coating.
Tool

Tool
Work Material

M6 x 1 2PM6 x 1 2P

SCM440 (30 HRC)

WorkDrill
Material
Hole Size

SCM440(30(Blind)HRC)
φ 5.52x 19 mm

LengthDrill Tapping
Hole Size

φ 5.52 x1219
mm
mm (Blind)Cutting
Speed
Tapping
Length

3012
m/min
mm

Coolant

Water-soluble Chlorine-free (5%)

Cutting Speed
Machine

30 m/minVertical Machining Center (BT30)

Coolant

Water-soluble Chlorine-free (5%)

MachineVertical Machining Center (BT30)

Figure 7. Performance of the new VI coating

11 SHAPE IT   Technical Insight

11,000 Large Wear

VI CoatingWear
12,000 Large11,000

VI Coating

Large Wear

12,000 Large Wear

V Coating

7,000 Large Wear

V Coating
0

2,000

4,000

0

2,000

6,000

8,000

7,000 Large Wear
10,000 12,000 14,000

Number of Holes Tapped

4,000

6,000

8,000

10,000 12,000 14,000

Number of Holes TappedCutting Data
Figure 8 depicts the A-XPF’s superior performance under high-speed machining condition at 30 m/min in alloy steel
with a hardness of 30 HRC. The A-XPF was able to complete 13,000 holes even in this machining range with stable
tool life.
Tool

Tool

Work Material

Drill Hole Size

M6 x 1 2P

Work Material

M6 x 1 2P

SCM440 (30 HRC)

φ 5.52x 19 mm (Blind)
SCM440 (30HRC)

Tapping Length
Cutting Speed

Tapping Length

Coolant
MachineCutting Speed

10,376 Large Wear

Vertical Machining Center (BT30)

Competitor A

Competitor B

Coolant

Water-soluble Chlorine-free (5%)

MachineVertical Machining Center (BT30)

0

2,000

2,200

9,000 Breakage

Large Wear

2,800

Large Wear

4,000

Competitor B

Figure 8. Cutting performance comparison in SCM440 (30 HRC)

13,0009,000 Breakage

Competitor A

Water-soluble Chlorine-free (5%)
12mm

30 m/min

13,00013,000 Large Wear

A-XPF

12 mm

φ 5.52 x 19 mm 30(Blind)m/min

Drill Hole Size

13,000 Large Wear

A-XPF

6,000

10,376 Large Wear

8,000

10,000 12,000 14,000

2,200

Large Wear

Number of Holes Tapped

2,800

Large Wear

Cutting Conditions

0
2,000 4,000 6,000 8,000 10,000 12,000 14,000
Table 2 shows the standard cutting conditions for the A-XPF. Compared to conventional products, the range of
Number of Holes Tapped
cutting speeds that can be used for mild steel, high carbon steel, alloy steel, and tempered steel has expanded
significantly. Suitable from low-speed machining to high-speed machining, the A-XPF is a versatile solution that canaccommodate a wide range of machining environment.
Cutting
Cutting
SpeedSpeed
A-XPFA-XPF

Work MaterialWork Material
Mild Steel
Mild・Steel
Low ・CarbonLow Carbon
Steel・Steel
Medium・Medium
CarbonCarbon
Steel Steel≦C0.4%≦C0.4%

10 ～1050～ 50 ◎ ◎◎Cutting
Cutting
SpeedSpeed
A-XPFA-XPF

Work MaterialWork Material（m/min）（m/min）（m/min）（m/min）

CopperCopperCu Cu

30～ 30 ◎ ◎10 ～10Brass・Brass
Brass・Casting
Brass Casting

Bs･BsCBs･BsC30～ 30 ◎ ◎10 ～10High Carbon
High Carbon
Steel Steel≧C0.45%≧C0.45% 10 ～10
40～ 40 ◎Alloy SteelAlloy SteelSCMSCM35～ 35 ◎ ◎10 ～10

Aluminum
Aluminum
RolledRolled
Steel SteelAl

Al

50～ 50 ◎ ◎20 ～20Hardened
Hardened
Steel Steel

25～35HRC
25～35HRC 5 ～ 30
5 ～ 30 ◎ ◎Aluminum
Aluminum
Alloy Casting
Alloy Casting

AC･ADC
AC･ADC50～ 50 ◎ ◎20 ～20Cast SteelCast SteelSC SC

40～ 40 ○ ○10 ～10Zinc Alloy
ZincCasting
Alloy CastingZDC ZDC30～ 30 ◎ ◎10 ～10

StainlessStainless
Steel SteelSUS304
SUS304
SUS420SUS4205 ～ 155 ～ 15 ◎＊1◎＊1

Best ◎BestGood◎ Good○ ○Note Note: The: indicated
The indicatedspeedsspeedsand feeds
and feeds
are foraretapping
for tappingwith chlorine-freewith chlorine-freewater-soluble
water-soluble
coolant.
coolant.

＊1 ＊: 1We :recommend
We recommend
usingusing
non-water-soluble
non-water-soluble
coolant
coolant
or highlyor highly
lubricatedlubricatedwater-soluble
water-soluble
coolant
coolant
for stainlessfor stainlesssteels.
steels.

Table 2. A-XPF Cutting Conditions

Productivity can be notably improved by the elimination of cutting
chips. Furthermore, with the A-XPF’s unique chamfer specificationand thread geometry, outstanding machining stability can beachieved. For manufacturers who are struggling with cutting chiptroubles in tapping, look to the highly efficient and multi-purpose
A-XPF forming tap to stay ahead of change.

Scan for details

SHAPE IT   Technical Insight 12

OSG’s 0.25-inch diameter WXL 2-flute ball nose end mill is used on the machining of Shadow Systems’ gun barrel fluting. With aproduction volume of 12,000 guns per month, the WXL end mill demonstrated eight times the tool life versus two other competitor tools.

Aim for Leaner and More
Efficient Manufacturing
WXL high performance carbide ball end mill reduces cycle time by half anddemonstrates eight times the tool life in 416 stainless steel gun barrel production
Ed Cawley
OSG USA
Established in 2016, Shadow Systems Corp. is a
privately held, Plano, Texas-based manufacturer ofpremium firearms. Shadow Systems’ products aredesigned and manufactured in the United States by ateam of veterans and former law enforcement officers.
With years of experience using firearms firsthand, theteam has carefully crafted a series of 9 mm handguns
with features and reliability that they have always
wanted in their own firearms. All of Shadow
Systems’ pistols are machined in-house at its
60,000-square-foot, state-of-the-art facility, whichhouses more than 40 vertical and horizontal CNC
machines along with 140 employees.
Shadow Systems CEO Trevor Roe has put together
a diverse management and production team thatbrings lean manufacturing experience from a myriadof industries. This allows the company to apply
manufacturing best practices not commonly foundin the firearm world, enabling Shadow Systems to beleaner and more efficient, which leads to competitive
pricing. Shadow Systems’ manufacturing approach
focuses on the principles of “built-in quality” and13 SHAPE IT   Customer Report“mistake proofing,” where every person who touches
a product during production is an inspector. When aproduct comes off the line, it has already benefited
from a thorough multi-point inspection before its
official inspection even begins. With a high standard in
quality and reliability, OSG tooling became a natural fit
for Shadow Systems’ manufacturing process.
DXP Enterprises, who is Shadow Systems’ tool supplier,has installed numerous vending machines on-site.
With the cooperation and support from DXP, OSG
has successfully proposed, tested and implemented
numerous high-performance tools that demonstrated
significant cost savings in Shadow Systems’ gun slideand barrel production.

Shadow Systems match-grade
spiral fluted barrels machinedfrom 416 stainless steel.
According to Shadow Systems,
the spiral fluting pattern
improves the evacuation ofdirt and debris and reduces
barrel weight. Photo courtesyof Shadow Systems.

1

2

3

1. From left, Shadow Systems CEO Trevor Roe, machine shop manager Jason Pettyjohn and Programmer Manager Scotty Whitmarsh, whohave been instrumental in allowing OSG the opportunity to test on some of their more challenging applications.
2. DXP Enterprises sales representative David Aly poses for a photograph at one of four vending systems at Shadow Systems. DXPEnterprises is Shadow Systems’ tool supplier and has installed numerous vending machines on-site. With the cooperation and support from
DXP, OSG has successfully proposed, tested and implemented numerous high-performance tools that demonstrated significant cost savingsin Shadow Systems’ gun slide and barrel production.
3. From right, before and after barrel fluting.

Shadow Systems’ gun slides are made of heat treated
17-4 stainless steel. In addition to high mechanicalstrength, 17-4 stainless steel is corrosion resistantand can be heat treated to optimal hardness levels.
The match-grade spiral fluted barrels are made of
416 stainless steel (JIS SUS416). According to Shadow
Systems, the spiral fluting pattern improves theevacuation of dirt and debris and reduces barrel
weight.
One application that particularly stood out was with
OSG’s EXOCARB® WXL 2-flute ball nose end mill usedon the gun barrel fluting. The EXOCARB® WXL(list number 3610) is OSG’s premium high performance
carbide ball end mill. Everything about the WXL isdesigned for rigidity and performance in wide variety
of materials and milling applications. Its substrates,
geometry and proprietary WXL coating are all
specifically tailored for nonferrous materials, mild
steels, and steels up to 50 HRC.

The EXOCARB® WXL is OSG’s premium high performance carbide
ball end mill engineered to excel in pre-hardened and hardened
steel applications.

Shadow Systems was originally using two othercompetitor 0.25-inch 2-flute ball nose end mills for theapplication. Shadow Systems knew of OSG from pastexperiences and was using other OSG tooling for otherparts of the gun. Shadow Systems was eager to further
reduce cycle time and cost in its production. With thesupport from the leaders of Shadow Systems and

DXP Enterprises sales representative David Aly, OSG
was given the opportunity to test the WXL ball noseend mill.
A Haas VF-2SS vertical machining center with a
40 taper spindle was used for the machining.
Water-soluble flood coolant was applied. A 0.25-inch
diameter 2-flute EXOCARB® WXL-EB (EDP# 36100611,
3-inch OAL, 0.25-inch LOC) was brough in for the
cutting trial to slot the fluting on the gun barrel. The
WXL ran at 14,750 rpm (294 m/min) and 32 ipm(813 mm/min), cutting cycle time per part from67 seconds to 34 seconds versus the competitor end
mills. With a production volume of 12,000 guns permonth, the time reduced is equivalent to a cost savingsof $99,540 USD annually. Moreover, the WXL end milldemonstrated eight times the tool life versus two othercompetitor tools. The WXL averaged 200 barrels while
the competitors both averaged 25 barrels. Although
the WXL end mill was twice the cost, it was able todemonstrate an annual cost savings of $278,580 USD
due to its exceptional tool life.
“I have always had great success running OSG tooling,”
said Shadow Systems programming manager Scotty
Whitmarsh. “But the WXL end mill performance wasabsolutely unbelievable compared to the othercompetitor end mills we tried.”
Shadow Systems is expanding rapidly, adding more
CNC machines and employees. As the company
continues its journey of growth, OSG will strive toprovide new tooling proposals to contribute to
Shadow Systems’ lean and efficient manufacturing.
SHAPE IT   Customer Report 14

More than 30 holes in various sizes are required to be threaded per valve body.

The First Choice
for Thread Milling
AT-1 thread mill enhances processing efficiency in hydraulic valve production
Hao Tian
OSG Shanghai

Thread milling often involves long cycle time andproblems of deflection. In order to resolve thesecommon obstacles, OSG has developed the AT-1 threadmill for high-quality threading, with two patented
technologies registered in Japan for its tool geometry.
The first patented technology is the AT-1’s left-handhelix geometry. Conventional right-hand helix threadmill is vulnerable to deflection as the cutting process
begins from the tip. In contrast, the AT-1’s right-hand cut
and left-hand helix geometry begins the cutting processfrom the shank side, thereby minimizes deflection. The
second patented technology is the unequal spacing
and variable lead flute geometry, which is commonly
applied in end mills. The unequal spacing and variable
lead flute geometry minimizes chatter. Applying theunequal spacing and variable lead flute geometry inthread mills involves a high degree of difficulty because
the thread pitch has to been adjusted accordingly to theflute geometry, which requires special manufacturing
techniques.

15 SHAPE IT   Customer Report

Recently, a manufacturer based in Nantong, Jiangsu
Province, China, whose name cannot be disclosed due
to confidentiality reasons, was able to leverage theAT-1’s superior thread milling performance in its
hydraulic valve production. Founded in 1996 andcurrently employing approximately 300 staff, thiscustomer specializes in the manufacturing and sales ofhydraulic control systems, electrical control systems,
hydraulic components, hydraulic machinery, hydraulicaccessories, pneumatic parts, and more.
This customer was seeking new tooling solutions
to improve the processing efficiency of its valve
body production, which the company has been
manufacturing since 2020. These hydraulic valves are
made of S45C and has an annual production volume of
50,000 pieces. More than 30 holes in various sizes are
required to be threaded per valve body. Each bottom
hole is a stepped through-hole. The depth of thethreaded hole on the valve body part is very close to
the bottom of the hole, so spiral taps cannot be used as
there is not enough room for the chamfer. The machineAT-1 Thread MillThread milling often involves long cycle timeand problems of deflection. In order to resolvethese common obstacles, OSG has developed
the AT-1 thread mill for high-quality threading,with two patented technologies registered inJapan for its tool geometry.
1

2

3

1. With the combination of the AT-1’s superior performance and OSG’s on-site technical support, processing time was halved in the hydraulicvalve thread milling application.
2. The customer was seeking new tooling solutions to improve the processing efficiency of its valve body production, which the company
has been manufacturing since 2020. These hydraulic valves are made of S45C and has an annual production volume of 50,000 pieces.
3. The machine used for processing is a Doosan vertical machining center BT50 with water-soluble coolant and hydraulic holder.

used for processing is a Doosan vertical machining
center BT50. Water-soluble coolant is applied duringmachining and a hydraulic holder is used. The
customer was originally using a domestic cutting tool
brand for the application. With the existing thread mill,corrections needed to be made multiple times during
processing, which affected the overall machining
efficiency.
OSG’s applications engineer learned of the situation
during a regular customer visit. Considering that S45C
is a relatively easy-to-cut material, OSG recommended
the AT-1 M10 x 1.5 thread mill (EDP# 8331007) andarranged a trial opportunity through a distributor.
For the first cutting test, the AT-1 was used at a
speed of 3,300 min-1 and a feed rate of 0.03 mm/t.
Several parts were processed, but performance wasunstable, with the size of the threaded hole being

either too large or too small. Upon a detail evaluationof the cutting condition, OSG’s applications engineer
recommended adding an additional pass with a radius
offset amount of 0.165 mm in the follow-up, which
successfully stabilized the machining. The original
thread mill required four cuts for each threaded hole.
The AT-1, on the other hand, only needed two cuts,
which halved processing time and improved theoverall processing efficiency. With the cutting trial
success, different sizes of the AT-1 thread mill are
implemented in the application.
With the combination of the AT-1’s superior
performance and OSG’s on-site technical support, thiscustomer is about to significantly reduce processing
time and hassle in its hydraulic valve thread milling
application.

SHAPE IT   Customer Report 16

From left, OSG Royco sales coordinator Francisco Arteaga, American Axle & Manufacturing de México tool engineer Manuel Cruz Valerio and
OSG Royco sales representative Oscar Morales pose for a photograph at AAM’s production facility in Silao, Guanajuato, Mexico.

Guaranteed Performance
OSG rack dies extend tool life and maintain production stability in automotive
high-volume parts with involute splines
Vanesa Aguilera, Francisco Arteaga and Oscar Morales
OSG Royco
Incorporated in 2006, American Axle & Manufacturing de México, S. de R.L.
de C.V. (AAM) is a part of the AAM corporate group headquartered in Detroit,
United States, with nearly 80 facilities in 17 countries. AAM is a leading
global tier 1 automotive and mobility supplier that designs, engineers andmanufactures driveline and metal forming technologies to support electric,
hybrid and internal combustion vehicles.

From left, steel spline yoke before and after
processing by rack dies. After machining,
splines are formed on the shaft.

17 SHAPE IT   Customer Report

American Axle & Manufacturing de México is located in Silao, Guanajuato.
Recently, AAM was troubled by undesirable rack dies life in its spline yoke
production used in motor vehicles. The spline yoke is made of steel and has anannual production volume of 500,000 pieces. AAM has been manufacturing
this part since 2019. Anderso-Cook spline rolling machines are used for theprocessing of these steel parts. The machines used are more than 10 years
old. At the time, many adjustments were required to be made to the machineduring processing, which took away productive time.

AAM originally used rack dies from two other cutting tool
brands. The competitor brands were chosen due to pricing.
However, with the competitor rack dies, AAM experienced
a great deal of variability in the processing, which required
numerous adjustments. AAM was also using one of thecompetitors’ regrinding services for the rack dies. Shim plates
were not attached to the reground rack dies, and AAM would
have to install them separately. Often the shims would comeoff, which required AAM to stop the machine to readjust.
An opportunity to test OSG rack dies came about when
OSG Royco sales coordinator Francisco Arteaga and sales
representative Oscar Morales visited AAM for several coating
applications in the factory. While Arteaga and Morales were at
the facility, they realized that AAM was troubled by the rack diesapplication and wanted to assist. AAM appreciated the offerand gave OSG Royco used rack dies to regrind. The performanceof the reground rack dies demonstrated significant
improvement and led to the trial of OSG Royco rack dies.
OSG rack dies are made from the highest quality steel andthe most modern engineering design to help manufacturers
optimize cutting processes. OSG’s rack dies are designed toeliminate the machine adjustment often required in die set up.
Simple die set up installation guarantees the perfect work piece,
reduces set up time and eliminates questionable parts. OSG
rack dies excel in applications involving rolling splines, threads
and grooves. Racks can be used individually or in combination
to roll multiple features, such as spline and groove.
A new pair of OSG rack dies measured 48 inches in length and4.25 inches in width were put to the test against the competitor
rack dies. The competitor rack dies averaged 25,000 pieces
in tool life. OSG’s rack dies, on the other hand, are able toachieve 65,000 pieces, which is more than double the tool lifeof the competitor. In addition to offering high quality toolingsolutions, OSG also helped AAM improve the condition of themachine to enable longer life in the rack dies.
“With OSG’s rack dies, the processing is much more stable,”said AAM tool engineer Manuel Cruz Valerio. “I don’t have to
make so many adjustments and the tool life of the rack dies has
improved,” Valerio adds.

12

1. Anderso-Cook spline rolling machines are used for theprocessing of spline yoke made of steel.
2. The competitor rack dies averaged 25,000 pieces in tool
life. OSG’s rack dies, on the other hand, are able to achieve
65,000 pieces, which is more than double the tool life of thecompetitor.

OSG Royco offers die reconditioning services at its
Guanajuato Tech Center (GTO Tech Center) in Guanajuato,
Mexico. Utilization of this program can lead to significant
cost savings over the cost of purchasing new tooling.
Rack dies are reconditioned by removing the existing
form profile and then regrinding a new profile. After
grinding, a shim plate is attached to the rack to bring it
into new rack dimensions.
OSG Royco’s reground rack dies demonstrate consistentquality with no variation. Moreover, Valerio is especiallypleased with OSG’s technical support.
“When we need a solution, it’s good to know that OSG
has a team of experts behind them,” said Valerio. “Theclose proximity of OSG’s facility in Guanajuato also
contributes to fast delivery time. It is a relief knowing that
help is near to solve any urgency,” said Valerio.

OSG Rack Dies

OSG’s rack dies are designed to eliminate the machine adjustment
often required in die set up.

OSG rack dies are made from the highest quality steel andthe most modern engineering design to help manufacturers
optimize cutting processes. OSG rack dies excel in applications
involving rolling splines, threads and grooves. Racks can beused individually or in combination to roll multiple features,such as spline and groove.

SHAPE IT   Customer Report 18

From left, OSG Sulamericana Regional Sales Leader Edson Veras, Imagem Automação Executive Director Paulo Krug, Imagem Automação CNC
Programmer Igor Limeira, Imagem Automação Production Manager Leonardo Rocha, and OSG Sulamericana Technical Sales Representative Allan
Siqueira pose for a photograph at Imagem Automação’s manufacturing facility in São José dos Campos, São Paulo, Brazil.

Turbocharge Performance
A-SIGMA-SFT spiral fluted tap and SynchroMaster tap holder accelerate productivity withreliable performance in carbon steel hub production
Lucas Sousa do Nascimento
OSG Sulamericana
Founded in 2018, Imagem Automação e Usinagem Ltda.
(Imagem Automação) is a manufacturer of machinery parts,
servicing markets such as aeronautics, defense, medical,
machinery and equipment, among others. Employing 40
staff, Imagem Automação’s facility is located in the city ofSão José dos Campos, São Paulo, Brazil, with an estimate
production area of 2,000-square-meter. Imagem Automação
is equipped with several 5-axis, 4-axis and 3-axis machining
centers, CNC lathes, milling machines, cylindrical and flat
grinders, as well as advanced inspection instruments toensure quality and accuracy in its production.
Recently, Imagem Automação was looking to improve thetool performance on its hub production for a manufacturerof high precision and performance machines and equipment.
The parts are made of SAE 1045 (JIS S45C) carbon steel andhas an annual production volume of 120 pieces. Fifteen
3/8-16 UNC-2B blind holes at a depth of 18 mm are required
to be threaded per part. The threads on the part are aligned
in several positions. All of the threading processes were
initially performed manually using hand taps introduced bya distributor. A hand tap set consists of three taps – taper tap,
19 SHAPE IT   Customer Reportplug tap and bottoming tap. The taper tap is used as a starter
tap, followed by the plug tap, and the blind hole is completed
by the bottoming tap. Occasionally, a tapping arm was used forthe first tap. However, for much of the time, all three processes
were performed by hand. Long cycle time of 225 minutes wasneeded to process one part with 15 threads, which included
setup time and tool change. Seeking to enhance productivity,
Imagem Automação reached out to OSG Sulamericana via a
professional network service provider.
Shortly after, OSG Sulamericana Regional Sales Leader Edson
Veras and OSG Sulamericana Technical Sales Representative
Allan Siqueira visited Imagem Automação to investigate themachining environment. Upon a detail evaluation of theapplication, the duo recommended switching from manual
processing to leveraging the company’s existing Mikron MILL
E700U 5-axis machining center. In terms of tooling, instead ofhand taps, OSG recommended the A-SIGMA-SFT spiral flutedtap (EDP# 49264124 - DIN 2183 3/8-16 UNC TiN) from the
A-Tap Σ (sigma) series along with the SynchroMaster tap
holder (EDP# 79913 - HSK63A-SMH-16-90), which is designed
to turbocharge tapping performance on CNC machines with

2

1

3

4

1. The A-Tap Σ (sigma) series includes the A-SIGMA-SFT spiral fluted tap for blind holes and the A-SIGMA-POT spiral pointed tap for throughholes. The A-Tap Σ features a sharp cutting edge to stabilize chip shape and a variable lead flute geometry to accelerate chip evacuation. Made of
HSS-E (JIS SKH53 equivalent) and coated with TiN, the A-Tap Σ is designed to excel in a wide range of work materials and cutting conditions withexcellent durability and wear resistance.
2. Right, OSG Sulamericana Technical Sales Representative Allan Siqueira explains the features of the A-Tap Σ (sigma) spiral fluted tap and theSynchroMaster tap holder.
3. All of the threading processes were initially performed manually using hand taps introduced by a distributor. Long cycle time of 225 minutes
was needed to process one part with 15 threads, which included setup time and tool change.
4. Imagem Automação is equipped with several 5-axis, 4-axis and 3-axis machining centers, CNC lathes, milling machines, cylindrical and flat
grinders, as well as advanced inspection instruments to ensure quality and accuracy in its production.

synchronous spindles by compensating for synchronization
errors during the threading process.
The A-Tap Σ (sigma) is a part of OSG’s well-known A-Tap
multi-purpose tap series. Developed in line with the core
concept of the A-Tap series with superior chip evacuation
capability, the A-Tap Σ is the new excellence for cost-effective
threading applications. The A-Tap Σ (sigma) series includes
the A-SIGMA-SFT spiral fluted tap for blind holes and the
A-SIGMA-POT spiral pointed tap for through holes. The
A-Tap Σ features a sharp cutting edge to stabilize chipshape and a variable lead flute geometry to accelerate
chip evacuation. Made of HSS-E (JIS SKH53 equivalent)and coated with TiN, the A-Tap Σ is designed to excel in awide range of work materials and cutting conditions withexcellent durability and wear resistance. The A-Tap Σ not only
excels in mid and high carbon steel and alloy steels, but isalso suitable for mild steel, stainless steel and aluminumalloy – materials that conventional general taps often
struggle with.
The SynchroMaster is a tap holder constructed to allow aslight amount of axial movement to compensate for axial
deviations that are unavoidable in rigid tapping. Its micro
tension-compression float eliminates the extra axial forceson the tap, leading to longer tool life, consistent tapping

depth and improved thread quality. The SynchroMaster tap
holder is especially recommended to manufacturers who arestruggling with unstable tool life, poor thread quality, low
productivity and large variations in depth length on rigid
tapped holes.
The 3/8-16 UNC A-SIGMA-SFT spiral fluted tap is used at a
cutting speed of 20 m/min and 668 rpm with soluble oil
coolant (8%). With the new machining arrangement andtooling combination, cycle time has been reduced from
225 minutes to 1 minute per part (15 threads), including timerequired for setup and positioning.
In addition to the dramatic reduction in cycle time, Imagem
Automação estimated that overall manufacturing time is
reduced by 32 percent per part. Moreover, tool breakage has
been minimized while thread quality has improved.
Imagem Automação is committed to the continuous
improvement of production processes, products andservices. By leveraging OSG’s A-SIGMA-SFT spiral fluted tap
and SynchroMaster tap holder, Imagem Automação is able
to accelerate productivity with reliable performance in its
hub production to guarantee the satisfaction of its clients.

SHAPE IT   Customer Report 20

AE-CPR-NDLC Coated Long Neck Corner Radius End Mill for Copper Electrodes

The AE-CPR-N is a long neck corner radiuscarbide end mill designed for high-efficiency
finishing of copper electrodes. Its 3-flute
specification contributes to high-efficiency
machining and long tool life. Moreover, the
AE-CPR-N’s unique flat cutting edge geometry,
superior corner R precision and cutting edge
diameter accuracy allow high precision
machined surface quality. With the additionof OSG’s DLC-IGUSS coating, long tool life andgood machining accuracy can be achievedin non-ferrous metals such as copper alloys,
which require welding resistance and lubricity.

The AE-CPR-N is available from diameter
0.2 mm to 6 mm with a wide variety of necklengths. Sizes up to diameter 1 mm employ a
2-flute specification. All sizes above diameter
1 mm are engineered with a 3-flute
specification.

PFDC
Facemill Disc Cutter for Small Machining Centers

The OSG Phoenix PFDC is a large-diameter disccutter engineered to excel in small machining
centers. It is constructed with a thin steel bodythat is lightweight and has high tool rigidity.
Even at diameter of 125 mm, the weightof the facemill arbor and tool total to only
1.9 kg. With an exceptional weight balance
design, the PFDC can be used on BT30 small
machining centers for high-speed rotary
machining. Due to its wide cutting width, the
PFDC is able to achieve uniform machined
surface with no seams in 1-pass, which isdifficult to achieve with conventional small
machining centers.

21 SHAPE IT   Product Pickup

The PFDC employs economical 4-corner insert
with 90-degree cutting edge and chip breaker
shape with sharp cutting edge engineered
to excel in non-ferrous metal and resin
applications.

ADO-TRS
3-flute Coolant-through Carbide Drill

The ADO-TRS is one of OSG’s latest drillinginnovations for ultra-machining efficiency ina wide range of materials. Its unique R gash
geometry enables high thrust resistance andexceptional chip control, which are common
challenges of 3-flute drills. With its low cutting
resistance capability comparable to 2-flute
drills, the ADO-TRS is able to create short andcompact chips stably. Furthermore, its wide
chip pocket configuration allows trouble-freechip evacuation even at high speeds andfeeds. With the addition of OSG’s original EgiAS
coating, superior wear resistance and long tool
life can be achieved.

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

OSG’s AT-2 carbide thread mill is developed
specifically to combine the drilling of apre-drilled 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 down 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 iscoated with OSG’s original DUROREY coating
to suppress chipping in high-hardness steel
applications.

SHAPE IT   Product Pickup 22

OSG Participates at CIMT 2023

OSG staff pose for a group photograph at CIMT 2023 at the China International Exhibition Center in Beijing. Uniformly dressed in a blue
20th anniversary jacket and a white polo shirt, sales and engineering staff from offices throughout China met with customers at CIMT
to provide face-to-face support.

OSG (Shanghai) Co., Ltd. (OSG China), OSG
Corporation’s subsidiary in China, participated at the18th China International Machine Tool Show (CIMT)
from April 10 to 15, 2023 at the China International
Exhibition Center in Beijing. Held every odd year,
CIMT is the largest and most influential machine
tool exhibition in China. It is also one of the fourlargest international trade fairs for machine tools in
the world, with similar popularity as EMO of Europe,
IMTS of the United States, and JIMTOF of Japan.
According to official data, more than 150,000 visitors
participated at CIMT 2023, an increase of nearly
27 percent versus the previous show.
At the show, OSG announced the release of the
A-XPF forming tap in the Chinese market andshowcased its latest A Brand product lineup in
combination with workpieces related to microprecision processing, automotive, aerospace, die andmold, and more.

The A Brand series was positioned at the centerof the OSG booth, an eyecatcher for every visitor
entering the area. The A-XPF, OSG’s latest highly
efficient and multi-purpose forming tap series, wasrevealed to the public in China for the first time at
CIMT 2023. The A-XPF was displayed at the center
stage of the A Brand product stand and manycustomers expressed interest to test the new tool.

1

The A-XPF, OSG’slatest highly efficientand multi-purpose
forming tap series, wasdisplayed at the center
stage of the A Brand
product stand.
2

1. Yukai Zhang, OSG Engineering Manager in Midwest China,
introduces A Brand products to visitors at the OSG booth at
CIMT 2023.
2. From left, OSG China Marketing Manager Vis Huang, Metal
Processing Magazine Vice President Xuelei Cao and OSG China
Marketing Specialist Yifan Zhang pose for a photograph at the
OSG booth at CIMT 2023 after an interview.

23 SHAPE IT   OSG News

Establishment of Special Subsidiary OSG Active
1. From left, OSG Active President
Hidenori Tanaka, Toyokawa City
Mayor Yukio Takemoto and OSG
Corporation President Nobuaki
Osawa pose for a photograph at
the Toyokawa City Hall in Aichi,
Japan.
2. An OSG Active employee
cleans tools at the Shinshiro
Factory in Shinshiro City, Aichi
Prefecture.
1

On December 13, 2022, OSG Corporation has
announced the establishment of OSG Active Co., Ltd.
as a special subsidiary that promotes employment
opportunity for people with disabilities. As a subsidiarythat is independent from the parent company, a work
environment with consideration of special needs canbe fostered. OSG is the only company to establish a
special subsidiary in Toyokawa City, Aichi Prefecture,and the first in the cutting tool industry in Japan.

2

OSG will continue to promote the creation of a societythat respects diversity regardless of one’s ability or
disability to enable every individual to play an activerole and shine in their respective work sites.
*A special subsidiary is a company established topromote and stabilize the employment of people withdisabilities.

OSG announces new sustainable forming tap
innovation “Green Tap”
At EMO 2023, held in Hannover, Germany from
September 18 to 23, 2023, OSG announced thedevelopment of “Green Tap,” a new revolutionary
forming tap innovation that contributes to therealization of a sustainable society.
Green Tap is made by OSG’s new and original
manufacturing method. Green Tap can minimize
the amount of electricity consumed during tap
manufacturing compared to conventional methods,
reducing CO2 emissions per tap by approximately
50 percent. In addition, the tool’s performance has
been improved due to its special tool geometry,enabling both eco-friendliness and efficient tapping.

OSG members from Japan and Europe pose for a group photo at the
OSG Booth on September 18, 2023 after a press event at EMO 2023.

OSG is making extensive efforts to attain its
environmental goals and is dedicated to creatinga sustainable future. Through the development ofGreen Tap, OSG strives to contribute to the realizationof a sustainable society by providing environmentallyfriendly products and making a positive impact on
the planet.
SHAPE IT   OSG News 24

OSG Around the World
Employee Interview with

Hakan Erdogan
Tell us about your background.
From the beginning of my career, I havealways been involved in the cutting tool
market. My father has been working in the
cutting tool industry since 1975. When I
turned 13 years old, I started working at
our family cutting tool business during thesummer holidays. The first OSG product that
I encountered was chaser dies. At the time,
it was one of the most famous products of
OSG in the Turkish market. After graduatingfrom Yıldız Technical University with adegree in mechanical engineering in 2000,
I began my journey in business. Between
year 2000 to 2012, I worked at my family
company Teknik Hırdavat Evi as a sales
engineer and later as a sales manager in
2008.

ProfileLocation: Turkey
Position: General Manager at OSG Turkey
Joined OSG: 2012
Motto: “Success is the result of your efforts. It’s never a coincidence.”

Tell us about your experience at OSG and your daily routine.
In 2012, I joined OSG through the company’s acquisition of my family business. With
the formation of OSG Turkey, I became general manager and a member of the OSG
Family, which I am proud of.
As the company’s general manager, I am responsible for all facets of operations.
My weekly routine usually begins with a Monday meeting with our sales manager,
customer service manager and accounting manager. My weekly agenda would
be scheduled based on their feedback. If there is no special event, I am usually inthe office to follow up on projects and reports revolving finance and production
to ensure strategic goals are met. For the remainder of the week, I would usually
make customer visits with my sales engineers that have scheduled meetings for me.
It could be any industrial area of Turkey. These customers are mostly key accountcustomers, dealers, or can be end users with major potential. In addition, OSG Turkey
would host at least one training session (technical, sales, etc.) every month at our
office, our dealers, or at customers. I always try to attend these training sessions andmeet with people face-to-face.
25 SHAPE IT   Meet OSG

Erdogan poses for a photograph at the52nd International Paris Air Show thattook place at the Le Bourget Parc desExpositions from June 19 to 25, 2017.
During the Paris Air Show, OSG exhibitedthe latest cutting tool solutions for theaerospace industry. In addition to theexhibition hall, VIP customers wereinvited to OSG’s chalet to enjoy aircraft
demonstrations.

1

2

3

1. Outside of work, Erdogan likes to spend time with his two daughters. They especially enjoy horse riding.
2 & 3. Erdogan suits up in his OSG kitesurfing gear, which he enjoys doing in the summer.

What is most challenging about your work?
Acquiring a large new customer account that we have never met before is always a challenge. It is a lengthy processthat requires many meetings, getting to know the customer, studying the parts that the client works with, choosing
the optimal OSG product, convincing the customer to try, conducting cutting trials, succeed in test trials anddemonstrating to the customer that OSG is better at cost per part, persuading the customer some more, and finallyissuing the invoice. The easiest part always comes after the first invoice is issued.
What is unique about OSG Turkey?
Dynamic teamwork is what makes OSG Turkey unique. We have ayoung team, but we also have been working together for many years.
The most important characteristic of our company is never giving up
under any condition. It is what contributes to OSG Turkey’s success
today.
OSG Turkey’s sales team poses for a photograph at the Maktek Eurasia 2022 show at
Tüyap Fair Convention and Congress Center in Istanbul, Turkey. Maktek Eurasia is aninternational fair that highlights the latest machine tools, tool holders, cutting tools,
measurement systems, software, manufacturing technologies, and more.

What is your favorite OSG tool?
I was most impressed by OSG’s FTO-GDXL, which is a revolutionary FX coated carbide long
drill with coolant holes that enables high-speed processing of 10 to 30 x D without pecking.
Developed in 2003, this tool demonstrated significantly greater efficiency and tool life thangun drills and HSS drills at the time. In 2007, we tried a 6 mm diameter 20 x D FTO-GDXL witha customer that manufactures crankshafts. This trial was the first deep hole drilling inTurkey and the FTO-GDXL drill was a new innovative product for all over the world.
After several tests, we succeeded and have greatly enhanced the customer’s
Developed in
production line, which was changed from transfer lines and HSS drills to CNC
2003, OSG’smachining centers and carbide long drills for deep holes. It was and still is the
FTO-GDXL is acoolant-through carbide
most productive drill effort I have ever made. I would like to once again thanklong drill that enables highMr. Gunnar Gumbach, who was responsible for Turkey at the time at OSG Europe,
speed processing of 10 to 30 x D
without pecking.
for providing immense support to me on this project.
How do you spend time on your day off?
I have two daughters, Melis, who is seven years old, and Lila, who is five years old. I like to spend time withthem playing, drawing, and watching movies. Our favorite activity is horse riding. I also enjoy kitesurfing in thesummer and snowboarding during the winter. I usually organize my vacations based on the best kitesurfing andsnowboarding spots from around the world.
SHAPE IT   Meet OSG 26