OSG Global Tooling Magazine

SUMMER 2022

Plastic Model of‘Tap-Kun’ Debuts
AE-BD-H and AE-LNBD-H carbide ball end
mills shape OSG popular mascot into 3D
format by injection molding
Technical Insight

OSG’s latest DLC
coated carbide end
mills for non-ferrous
metal applications

Customer Report

The Winning Choice
ADO-TRS 3-flute coolant-through carbide drill and
VPO-DC-MT synchro tap enable stable drilling andtapping in the production of planetary bearing
hubs for gearmotors in spheroidal cast iron

Meet OSG

Employee Interview
in USABecoming an Essential Player of
the Global Manufacturing Industry
A Message from the President
Earlier this year, OSG announced its new medium-term
management plan “Beyond the Limit 2024.” The phrase“Beyond the Limit” signifies OSG’s determination to
evolve by challenging the status quo, setting no limit,
and to break through conventional wisdom. A “Beyond
the Limit” logo has been created to enhance recognition
and to further promote OSG’s goals. As depicted on
the upper right corner, the logo is made up of two key
elements – a black frame that symbolizes our current
limit, and a blue box that rises beyond the boundary.
Looking ahead to the carbon-neutral era, which will
accelerate further in the future, OSG will strive to achieve
its long-term vision of becoming an “essential player”(an indispensable manufacturer) that contributes to theglobal manufacturing industry.
OSG’s new medium-term management plan is aimed
at the year 2030, which is regarded as a key milestone
globally for carbon neutrality. OSG will achieve its longterm vision through actions by stages, where 2022 to2024 is accounted as stage one, 2025 to 2027 as stage
two, and 2028 to 2030 as stage three.
In the fiscal year ended November 2021, the global
economy exhibited a recovery trend. However, theimpact of the coronavirus pandemic continues to
disrupt the supply chain of the manufacturing industry.
Despite challenging circumstances, OSG is able to recover its business performance to the same level as in the fiscal year
ended November 2019 with its globally expanded supply system. To navigate through the current ambiguous VUCA* era, OSG
will focus on ESG (environmental, social and corporate governance) management to realize a sustainable society under the
corporate philosophy of “global presence” to pursue long-term growth with the aim of increasing corporate values.
In order to respond to major industrial reforms that are expected to take place in the future, OSG will integrate its strengths
such as product development, manufacturing, sales, regrinding and coating, to focus on fast growing industries including
precision manufacturing, semiconductor, 5G, electric vehicle, green energy and medical. The company will also work tostrengthen governance and to promote diversity and inclusion in the workplace. OSG will strive to achieve goals of the new
medium-term management plan “Beyond the Limit 2024” to continue to support the manufacturing industry worldwide.
*VUCA is an acronym for volatility, uncertainty, complexity and ambiguity.

Nobuaki Osawa
President & COO of OSG Corporation

1

SHAPE IT   ﻿CONTENTS Feature
SHAPE ITSUMMER 2022

3 Plastic Model of ‘Tap-Kun’ Debuts

Technical Insight
11 OSG’s Latest DLC Coated Carbide End Mills for Non-ferrous Metal Applications

Customer Report
15 The Winning Choice
19 Powerful and Economical

Product Pickup
21 AE-VMFE Carbide End Mill, OSG Phoenix PDZ Indexable Flat Drill
22 AE-ML-H Long Carbide End Mill, AE-VTFE-N Carbide End MillOSG News
23 OSG Offers COVID-19 Vaccine to Employees, Employee Families and Members ofAffiliate Companies

24 MECT 2021

Meet OSG
25 Employee Interview in USA

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: July 2022
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

1

Plastic Model of‘Tap-Kun’ Debuts
AE-BD-H and AE-LNBD-H carbide ball end mills shape OSG popular mascot into
3D format by injection molding
Kaori Sato
OSG Corporation

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SHAPE IT   Feature

2

3

1. An assembled Tap-kun plastic
model, measuring approximately
35 mm wide, 40 mm tall and 25 mm
long.
2. The mold of Tap-kun’s head.
3. The mold of Tap-kun’s body.

Plastic Model Kit
Plastic models are scale models that are generally
manufactured as kits that can be assembled straightfrom the box and are intended for static display.
Japanese plastic model kits are especially popularamong hobbyists due to their superior quality andhigh accuracy in replication.

Manufacturing Process
Injection molding is the predominant manufacturing
process for plastic models produced in large volume.
Polystyrene (PS), a hard solid plastic, is commonlyused in injection molding of plastic models due to its
lightweight and outstanding dimensional stability
characteristic. Polypropylene (PP), one of the mostfrequently produced thermoplastics in the world,is also used due to its unique properties and ability
to adapt to various fabrication techniques. Bothpolystyrene and polypropylene are ideal materials
as they can be liquified, easily injection molded andsubsequently recycled. Because of the high costs ofinjection molding equipment, however, small-scale
plastic model productions are often manufactured
using alternative methods such as resin-casting.

AnjoHeartsProject
Anjo is a city located adjacent to Toyota city incentral Aichi Prefecture. It is one of Japan’s leading
manufacturing cities, where automobile-related
supporting industries thrive. Although many small andmedium-sized manufacturers with high technologicalcapabilities are concentrated in the region, they
are easily affected by overseas production trends
and the business condition of major automobile
manufacturers. Feeling the need to foster an industry
that does not rely solely on automobiles, theAnjo Chamber of Commerce launched a regional
brand called “AnjoHeartsProject” in 2010. Comprisingmore than 10 companies, the AnjoHeartsProject
strives to bring together collective strengths of local
manufacturers to deliver new industrial products fullof dreams and love while taking close consideration of
the global environment.

SHAPE IT   Feature41

1. From left, Yuichi Ishikawa, Yoshikatsu Koshitori, Takehiro Hayakawa, President Masahide Takaki, Nobuo Negita, Kentaro Norose andManufacturing Engineer Hideki Takaki pose for a group photo at the production facility of Takaki Kanagata in Anjo, Aichi Prefecture.
2. From left, Fujii Kakou President Kiyomitsu Fujii and Fujii Kakou CEO Tatsuo Fujii pose for a photograph in Anjo, Aichi Prefecture.
3. Ichitake Kougyousyo President Tatsuya Takeguchi poses for a photograph at the company’s manufacturing facility in Nishio, Aichi
Prefecture. Ichitake Kougyousyo is a manufacturer with over 40 years of experiences in injection molding of thermoplastic resin for a wide
variety of products including automotive parts, appliances and other common goods.

YUME ‘Dream’ Plastics & Custom Model Kits
One of AnjoHeartsProject’s most famously known
initiatives is the regeneration of plastic bottle caps
into custom plastic model kits that companies wouldpurchase as novelties. Materials used for the plastic
models are made from used plastic bottle caps, which
are made of polypropylene. The Anjo city collects morethan 6 million plastic bottle caps per month and ranks
as one of Japan’s top environmentally friendly cities.
Once collected, the caps are sorted by color and arebrought to the recycling site at Fujii Kakou Co., Ltd. tobe crushed and regenerated. The recycled material is
cut into small pellets, and a new type of eco material isborn. The AnjoHeartsProject named the regenerated
material as YUME ‘dream’ plastics, which is certified
by the Japanese government as a regional industrial
resource. The YUME plastics are melted and poured into
a designated mold, where custom plastic models aretransformed into shape.

5

SHAPE IT   Feature

The AnjoHeartsProject is composed of industrial
professions who are specialists in raw materials, dieand mold design and manufacturing, and injection
molding. Raw material is handled by Fujii Kakou Co.,
Ltd., a professional of recycled plastic raw materials.
The design and manufacturing of the die and mold forthe plastic model is assigned to Takaki Kanagata Co.,
Ltd., a company that specializes in the manufacturingof die and mold for automotive parts. Last but notleast, the prototype and plastic molding process isadministrated by Ichitake Kougyousyo Co., Ltd., amanufacturer with over 40 years of experiences ininjection molding of thermoplastic resin for a wide
variety of products including automotive parts,
appliances and other common goods.

2

3

6

4

5

7

8

4. Materials used for the plastic models are made from used plastic bottle caps, which are made of polypropylene. The Anjo city collects
more than 6 million plastic bottle caps per month and ranks as one of Japan’s top environmentally friendly cities.
5. Once collected, the caps are sorted by color and are brought to the recycling site to be crushed and regenerated.
6. A worker at Fujii Kakou pushes the used bottle caps into a machine to be crushed.
7. The recycled material is cut into small pellets, and a new type of eco material is born. The AnjoHeartsProject named the regenerated
material as YUME ‘dream’ plastics, which is certified by the Japanese government as a regional industrial resource.
8. The regenerated pellets are sorted by color and are designated for specific usage.

Project Partners
Fujii Kakou Co., Ltd.
Location: Anjo, Aichi Prefecture
Year established: 1979
Main product / services: recycling of plastic raw materials
Representatives: Tatsuo Fujii, CEO and Kiyomitsu Fujii, President
Company website: http://www.fujii-kakou.co.jp/

Takaki Kanagata Co., Ltd.
Location: Anjo, Aichi Prefecture
Year established: 1991
Main product / services: die and mold design and manufacturing
Representative: Hideki Takaki, Manufacturing Engineer
Company website: http://www.takaki-kanagata.jp/

Ichitake Kougyousyo Co., Ltd.
Location: Nishio, Aichi Prefecture
Year established: 1976
Main product / services: injection molding of thermoplastic resin
Representative: Tatsuya Takeguchi, President
Company website: https://ichitake.co.jp

SHAPE IT   Feature

6

Shaping OSG’s Brand Mascot ‘Tap-Kun’
into 3D Format
OSG Corporation’s headquarters is located in thecity of Toyokawa, Aichi Prefecture, which is only
about an hour away from Anjo by car. In early 2019,
OSG learned of the AnjoHeartsProject through abusiness acquaintance and decided to collaborate
to create an original plastic model kit of its popularmascot Tap-kun as a novelty. Tap-kun is OSG
Corporation’s official brand mascot. It is a fictional
cutting tool character based on the imagery of ahand tap, which is the first product of OSG since its
founding in 1938. The friendly hand tap character
Tap-kun serves as OSG’s brand ambassador in the
promotion of the company, the manufacturingindustry and local communities. In the past
couple of years, Tap-kun has gained substantial
recognition and popularity in the manufacturingindustry in Japan and around the globe.
As a manufacturing company located in thesame region, OSG greatly empathizes with the
AnjoHeartsProject’s mission and wanted to support
the initiative by supplying work materials andcutting tools for manufacturing the die and moldof its plastic model.

1

Tap-kunTap-kun is OSG Corporation’s official
brand mascot. It is a fictional cutting
tool character based on the imagery ofa hand tap, which is the first product of
OSG since its founding in 1938.

2

1. A sketch of OSG’s custom Tap-kun plastic model by
Takaki Kanagata.
2. 3D modeling of OSG’s mascot Tap-kun by Takaki Kanagata.

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SHAPE IT   Feature

Manufacturing Process

Tap-kun face convex surface finish (contour milling)
Tool used: AE-LNBD-H (R1.5 x 25 x 6)
Material: STAVAX (53 HRC)
Cutting parameters: n 10,000 rpm (Vc 94 m/min), Vf 800 mm/min(fz 0.04 mm/t), ap 0.1 mm ae 0.1 mm
Machine: OKUMA MB-56VA

OSG placed an order of 5,000 model kits from theAnjoHeartsProject. In order to create an original
plastic model kit, a number of steps are required,such as 3D modeling of the designated character,die and mold creation, and injection molding.
The 3D modeling, die and mold design andmanufacturing are handled by Takaki Kanagata.
OSG recently released a new carbide ball end
mill series dedicated for high-hardness steel
applications. In hopes to share the company’s latest
milling innovation, OSG supplied its premium
tooling and STAVAX stainless mold steel for the
project.

AE-BD-H and AE-LNBD-H Carbide Ball
End Mills for High-hardness SteelApplications
OSG’s AE-BD-H is a 2-flute carbide ball end milldesigned for high-precision finishing. It features avariable negative spiral gash for better chipping
control. The AE-BD-H’s superior ball R precision
ensures a stable radius accuracy across180 degrees. The AE-LNBD-H is a 2-flute long neckcarbide ball end mill designed for high-precisionfinishing. Similar to the AE-BD-H, it also featuresa thick center core to help prevent deformationof the ball tip to improve chipping control. Its
teardrop-shaped outer periphery strong back taper
geometry enables milling by point, which prevents
chattering and chipping, resulting in improvementof surface accuracy. Both carbide ball end mills arecoated with OSG’s original DUROREY coatingwith superior heat resistance and hightoughness optimized forhigh-hardness steels.

AE-BD-H and AE-LNBD-H
The AE-BD-H and AE-LNBD-H are OSG’s latest carbide
ball end mills engineered for high-hardness steel
applications with capabilities to contribute to fastermold production and higher precision.

SHAPE IT   Feature

8

Takaki Kanagata machine operator Yuichi Ishikawa prepares for the milling of OSG’s custom Tap-kun plastic model mold made of STAVAX.

Application Details
Takaki Kanagata is accustomed to using S50C carbon
steel for the die and mold production of plastic
models. Although the company has used STAVAX forother part production in the past, it was the first time
for the company to utilize STAVAX in plastic model
production.
“It was a rare application with a number of
uncertainties in terms of material, processing andtooling,” said Hideki Takaki, Manufacturing Engineer
at Takaki Kanagata. “We felt excited and uneasy at thesame time,” Takaki adds.

1

Takaki Kanagata was not familiar with OSG milling
tools and was initially concerned about the processingof Tap-kun’s head, which requires the milling ofmultiple narrow paths. To their surprise, the AE-BD-H
and AE-LNBD-H performed as advertised.
“These end mills are really made to excel in highhardness steels,” said Takaki. “The surface quality was
excellent.”
Takaki adds that it was a nice project for the company,and he was glad to be able to collaborate with OSG.

9SHAPE IT   Feature2

1. The completed Tap-kun plastic model moldmade of STAVAX by Takaki Kanagata is transferred
to Ichitake Kougyousyo to be injection molded
utilizing the regenerated material YUME ‘dream’
plastics.
2. A fleet of Tap-kun custom plastic models aretransformed into shape at Ichitake Kougyousyo.

OSG creates a number of promotional merchandises
annually to give to customers during special
occasions and events. The collaboration with the
AnjoHeartsProject, however, is especially meaningful
as the parts are made of 100 percent recycledmaterials.
“Plastic model kits stimulate the motivation tocreate. They are highly engaging, fun and advocate
communication through the assembly of the model,”said OSG Corporation Marketing Supervisor
Daiki Nakamura.

From left, cap arts of OSG Corporation’s A Brand logo and official
brand mascot Tap-kun. Instead of simply recycling used bottle
caps, AnjoHeartsProject created an initiative to create art withthem to encourage communication regarding the environment.

“More importantly, through meaningful
collaborations, we hope to share technical expertise,
spread awareness about the environment and to shareknowledge about how to become a more sustainable
society to create a better tomorrow for future
generations,” Nakamura adds.

OSG Corporation applications engineer Masaki Hosono completes a cap art of OSG Corporation’s official brand mascot Tap-kun. Hosono
provided technical support to Takaki Kanagata in the crafting of Tap-kun’s plastic model mold made of STAVAX.

SHAPE IT   Feature 10

AE-TS-N, AE-TL-N
and AE-VTS-N
OSG’s latest DLC coated carbide
end mills for non-ferrous metal
applications
Akira Harada
OSG Corporation Applications Engineer(End Mill Development Division)
In recent years, markets that make heavy useof aluminum alloys, such as electric vehicles,industrial robots and semiconductor,
have expanded tremendously. The surge
in aluminum alloy applications has also
driven higher demand for effective cutting
tools to process these materials. Aluminum
workpieces often come in various sizes andforms. Thus, the specification required of
the cutting tools would vary depending on
the individual application. In order to meetthe rising industry trend, OSG has recently
developed three new types of millinginnovations to fulfill these needs.

AE-TS-N & AE-TL-N:
Standard Type End Mills
Until now, end mills used for processing
non-ferrous metals such as aluminum alloys havegenerally been non-coated 2-flute or 3-flute. It
was the industry standard for 3-flute DLC coatedend mills to be high-spec but expensive. OSG’slatest AE-TS-N and AE-TL-N are developed todisrupt the established status quo. Categorized
as standard items, these end mills are 3-flute, DLC
coated, and are equipped with the most suitable
tooling specifications for non-ferrous metal
processing. Furthermore, the pricing of thesetools is overwhelmingly reasonable compared
to conventional DLC coated carbide end mills for
non-ferrous metals, and even more competitive
versus conventional non-coated products.
Despite being equipped with advanced toolingspecifications, OSG is able to achieve competitive
pricing by being strongly aware of manufacturingcosts from the development stage, establishinghighly productive product configurations, andthoroughly improving the efficiency of the
manufacturing process. Figure 1 illustrates acomparison of the flute shape of the AE-TS-N
versus a conventional product. Production costs
have been reduced by using a formed grinding
wheel to shorten the flute grinding time. In
addition, the AE-TS-N is engineered with thelatest flute shape that can secure smooth chip

11 SHAPE IT   Technical InsightAE-TL-N

AE-TS-N

evacuation while improving rigidity by making the core
thickness larger than the conventional product.
The AE-TS-N has a 1.5xD length of cut and a neck length of
3xD. It is designed to excel in deep milling applications while
ensuring rigidity. The AE-TL-N is a long length of cut version of
the AE-TS-N that is engineered for side milling and finishing. It
is available in length of cut of 3xD and 5xD. With these three
types of specifications, manufacturers are able to select themost appropriate product based on application needs.

Figure 1. Comparison of flute shape between AE-TS-N anda conventional product

AE-TS-N

Conventional

50%

38%

Arrow: indicates chip discharge direction

SHAPE IT   Technical Insight 12

AE-VTS-N

AE-VTS-N: High Performance Type End Mill
The AE-VTS-N is a product developed for manufacturers who
desire high efficiency milling performance. With the variable
lead and unequal spacing teeth tool geometry, chatter is lesslikely to occur even under aggressive cutting conditions. The
AE-VTS-N is also effective for plunging and ramping in thez-axis direction. Furthermore, by adopting a wiper flat cuttingedge and micro primary relief specifications, higher precision
machined surface quality can be achieved in addition toefficiency.
For the tool coating, the AE-TS-N and AE-TL-N use the
DLC-SUPER HARD coating that emphasizes on sharpness;while the AE-VTS-N uses the DLC-IGUSS, which is one of OSG’slatest coatings that is thicker and has better wear resistancethan the DLC-SUPER HARD coating, making it an ideal coating
for the AE-VTS-N, as it is an end mill engineered to excel underaggressive milling conditions.

13 SHAPE IT   Technical InsightThe AE-TS-N, AE-TL-N and AE-VTS-N can be applied not only
to aluminum alloys but also to non-ferrous metals such ascopper and magnesium and have a proven track record of
excellence in processing non-metals such as acrylic resin. This
DLC coated end mill series is developed with the concept ofbeing able to accommodate all of the above materials with asingle tool.
With superior performance and an abundant product lineup,
OSG’s latest DLC coated end mill series strive to overturnconventional wisdom of non-ferrous metal end mills by
providing new solutions based on budget and individual
application needs.

Scan for details

SHAPE IT   Technical Insight 14

From left, OSG Italia Sales Engineering and Marketing Manager Andrea Severi, MPC owner Stefano Soldati and MPC machine operator Lucapose for a photograph at the MPC facility in San Giorgio di Cesena, Emilia- Romagna, (FC), Italy.

The Winning Choice
ADO-TRS 3-flute coolant-through carbide drill and VPO-DC-MT synchro tap enablestable drilling and tapping in the production of planetary bearing hubs for gearmotors
in spheroidal cast iron
Andrea Severi
OSG Italia

Time savings in the production of large-size
components can often make a significant difference toa manufacturer’s bottom line. Achieving a 50 percent
reduction in tapping time was one of the recent key
objectives of MPC Srl of Cesena (FC), Italy, a precision
machining company that is always attentive to newtechnologies and process optimizations.
Founded in 1973, MPC is a leading solution provider ofprecision mechanical machining. MPC’s core business

15 SHAPE IT   Customer Reportfocuses on the production of gearbox components
and corresponding parts. With over 40 years ofexperience, MPC has established a name for itself
within the earthmoving and wind energy sectors. In
addition to precision machining, the company is alsoversed in processes such as milling, turning, drilling
and assembly, as well as custom manufacturing
requests that fall within the metalworking andprecision engineering sectors.

Today with 36 full-time employees, MPC’s manufacturing
facility is located in San Giorgio di Cesena,
Emilia- Romagna, (FC), Italy, with an estimate
3,000-square-meter production space. MPC is a specialistin large-scale machining and has a production facility thatis capable of turning parts up to 1,300 mm in diameter. Its
factory is equipped with 23 numerical control machines
including lathes and machining centers, with capabilities
to optimize work cycles of large components in small to
medium size batches.
Recently, MPC was looking to improve tool performanceon a component made of GS-600 cast iron for aworld-renowned client of gearmotors, drive systems andplanetary gearboxes. Each part requires the threadingof 30 holes in the size of M24 x 3, tolerance 6HX andat an axial depth of cut of 40 mm (through hole). The
production is a 4-year contract with an estimated annual
volume of 2,000 pieces.
MPC was originally using a competitor tap for the part,but encountered problems of sticking, bad surface finish
and poor tool life. After consulting with its local tooling
distributor Utensilmec, MPC invited OSG Italia’s technician
to optimize the application with an aim to improve cycle
time, tool life and the quality of threads.

Founded in 1973, MPC is a leading solution provider of precision
mechanical machining. MPC’s core business focuses on the
production of gearbox components and corresponding parts.
With over 40 years of experience, MPC has established a namefor itself within the earthmoving and wind energy sectors.

Upon a detail evaluation of the application, OSG
recommended the VPO-DC-MT (EDP#: T0809234)
M24 x 3 synchro tap with radial lubrication. The
VPO-DC-MT is a powder metal straight fluted tap
engineered to excel in cast iron and aluminum die
cast applications. The high rigidity geometry of thistool combined with OSG’s V coating and the highly
wear resistant powder metal substrate guarantee
high-performance process stability.

MPC’s MCM Tank horizontal machining center with HSK-A100 holder that is used for processing planetary bearing hubs for gearmotors.

SHAPE IT   Customer Report 16

OSG’s M24 x 3 VPO-DC-MT synchro tap is mounted in the spindle for the production of a GS-600 cast iron component.

The VPO-DC-MT is mounted on a Big Kaiser
micro-compensated tap holder with a total presettingof 415 mm. The tool is programmed in an MCM Tankhorizontal machining center and an ESSEX AR35
coolant is used. By switching to the VPO-DC-MT, theprocessing efficiency in cutting speed has doubled
from the competitor’s 15 m/min to 30 m/min. The
VPO-DC-MT is able to complete 5,000 threads for a
total of 200 linear meters versus the original tool’s
1,660 threads for a total 67 linear meters. Comparing
the cutting parameters of the previous tap,
three minutes of cycle time can be saved per pieceby simply switching to the VPO-DC-MT, which isequivalent to an annual cost savings of approximately
9,000 euros. Moreover, the VPO-DC-MT is able totriple tool life, which is an additional reduction intooling cost. Last but not least, the surface quality ofthe thread crests has significantly improved, and chip
sticking has been completed eliminated.

17 SHAPE IT   Customer Report

MPC couldn’t be more satisfied with the result, andOSG was given with another opportunity to analyze
tooling performance of an eccentric hub. The second
component is made of GS-500-7 cast iron. Each part

Components for gearboxes made of GS-600 cast iron. Each part
requires the threading of 30 holes in the size of M24 x 3, tolerance
6HX and at an axial depth of cut of 40 mm (through hole).

requires the threading of 24 holes in the size ofM20 x 2.5, tolerance 6HX and at an axial depth of cut
of 40 mm (through hole). The production is a 5-year
contract with an estimated annual volume of 1,000
pieces. Similar to the first GS-600 cast iron component,
MPC was originally using a competitor tap for the
production, and encountered problems such as
chip sticking, bad surface finish and poor tool life. To
further improve cycle time, OSG recommended the17.5 mm diameter ADO-TRS-3D 3-flute carbide drill(EDP#: 8721750) and the VPO-DC-MT M20 x 2.5 tap
with central lubrication (EDP#: 48300228).
The ADO-TRS is one of OSG’s latest drilling innovations
for ultra-machining efficiency in a wide range ofmaterials. The ADO-TRS’ 3-flute specification offers
greater balance than 2-flute drills, which are more
prone to chattering. Moreover, the ADO-TRS enables
superior roundness and improved positioning interms of hole precision. With capability to excel underhigh-feed condition, the ADO-TRS is able to minimize
contact time with the workpiece material, which
reduces the probability of work hardening.

The VPO-DC-MT also exhibits similar increases
in performance, where processing efficiency has
doubled from the competitor tap’s 15 m/min to
30 m/min in cutting speed. The VPO-DC-MT is able tocomplete 5,300 threads for a total of 212 linear meters
versus the original tool’s 1,700 threads for a total
68 linear meters. Two minutes of cycle time can besaved per piece by switching to the VPO-DC-MT, whichis equivalent to an annual savings of approximately
3,000 euros. Similar to the first component, the
VPO-DC-MT is able to triple tool life in the processingof the cast iron eccentric hub, which enables
additional reduction in tooling cost.
MPC is always ready to satisfy the requests of its
present and future clients by keeping up to date withthe very best technologies available on the market.
With significant cycle time reduction and quality
improvement, OSG’s ADO-TRS 3-flute carbide drill and
VPO-DC-MT synchro tap have demonstrated to be thewinning choices for MPC.

The ADO-TRS is highly recommended to be usedin combination with the VPO-DC-MT synchro tap
to achieve flawless holes for perfect threading. This
combination of tools makes it possible to significantly
reduce cycle time while maintaining superior quality.
The ADO-TRS 3-flute carbide drill is mounted on ashrink-fit chuck from Big Kaiser with a total presettingof 305 mm. The VPO-DC-MT M20 x 2.5 synchro tap
is mounted on a Big Kaiser micro-compensated tap
holder with a total presetting of 370 mm. The tools
are programmed in MPC’s MCM Tank horizontal
machining center and an ESSEX AR35 coolant is used.
MPC was originally using a competitor 2-flute drill forthe drilling process. The parameters of the competitor
drill are 70 m/min in cutting speed, 0.3 mm/rev in feed
per revolution, 1,274 rpm in spindle speed and382 mm/min in table feed. By switching to the
ADO-TRS, the cutting parameters are boosted to
90 m/min in cutting speed, 0.65 mm/rev in feed per
revolution, 1,637 rpm in spindle speed and1,074 mm/min in table feed, which is equivalent to a181.2 percent increase in feed. The overall cycle time is
reduced by 65 percent.

12

1. An eccentric hub component made of GS-500-7 cast iron. Eachpart requires the threading of 24 holes in the size of M20 x 2.5,
tolerance 6HX and at an axial depth of cut of 40 mm(through hole).
2. OSG’s 17.5 mm diameter ADO-TRS-3D 3-flute carbide drill ismounted in the spindle for the production of the eccentric hub
component made of GS-500-7 cast iron.

SHAPE IT   Customer Report 18

OSG’s custom A-SIGMA-OIL-SFT spiral fluted tap helps improve tool performance in Tecparts’ production of welded pins used in tractors forthe heavy industry, which the company produces approximately 200 to 220 pieces per month.

Powerful and Economical
Custom A-Tap Sigma spiral fluted tap takes quality and reliability to the next level intractor component production
Rodrigo Katsuda
OSG Sulamericana

Founded in 2003, Tecparts do Brasil Industria e Comercio
Ltda. (Tecparts) is a part supplier for the agricultural,
automotive and wind power industries. Employing
294 staff, Tecparts is located in the city of Piracicaba,São Paulo, Brazil, with an estimate plant area of
30,000-square-meter.

SAE-4140 steel, each welded pin requires the threading ofa M30 x 3.5 single blind hole at a tapping length of
38 mm, a drill hole size of dia. 26.5 mm x 47 mm, and witha tap tolerance of 6GX. The parts are machined using a
Doosan DVC-400 vertical machining center, running at a
cutting speed of 8 m/min with synthetic soluble oil.

Recently, Tecparts was looking to improve tool
performance on the production of welded pins used intractors for the heavy industry. Tecparts manufactures
a wide range of components for tractors with morethan 400 items, including pins, bushings, joints, covers,
housings, shafts, switches, levers, special screws,
transmissions, among others. Tecparts has been
manufacturing this part since early 2018 with an annual
estimate production volume of 2,500 pieces. Made ofTecparts was originally using a competitor HSS-E spiralfluted tap with TiN coating for the job but experienced
calibration problems, low yield and poor tool life. Aftera number of visits and product introduction by OSG
Sulamericana’s sales technician, Tecparts decided to put
an OSG custom A-Tap A-SIGMA-OIL-SFT(D376 M30 6GX TiN) to the test.

19 SHAPE IT   Customer ReportA-SIGMAThe A-Tap Σ (sigma) is the latest addition to the A-Tap multi-purpose tap
series. Developed in line with the core concept of the A-Tap series withsuperior chip evacuation capability, the A-Tap Σ is the new excellence forcost-effective threading applications.

The A-Tap Σ (sigma) is the latest addition to OSG’swell-known A-Tap multi-purpose tap series. Developedin line with the core concept of the A-Tap series withsuperior chip evacuation capability, the A-Tap Σ is the new
excellence for cost-effective threading applications. The
A-Tap Σ series include 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 cuttingedge to stabilize chip shape and a variable lead flute
geometry to accelerate chip evacuation. Made of HSS-E
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.
Under identical cutting parameter as the previous toolingchoice, the custom A-Tap A-SIGMA-OIL-SFT is able toeliminate the calibration issue that Tecparts was troubled

by. Moreover, the custom A-SIGMA-OIL-SFT is able tofurther increase tool life from 204 holes to 275 holes.
Due to the reduction of tool changes, overall processing
time can also be minimized. With this success, OSG
Sulamericana today supplies 100 percent of the highperformance and special taps used at the entire Tecparts
production line.
The A-Tap Σ not only excels in mid and high carbon steel
and alloy steels, but is also suitable for mild steel, stainlesssteel and aluminum alloy – materials that conventional
general taps often struggle with. With guaranteed
reliability and simplified tool management, the A-Tap Σ isthe new economical choice for a wide variety of threading
applications.

Responsible for Tecparts’ tooling,
Rodrigo Amaral prepares forthe machining of the welded
pins. Tecparts manufactures awide range of components for
tractors with more than 400
items, including pins, bushings,
joints, covers, housings, shafts,
switches, levers, special screws,
transmissions, among others.

SHAPE IT   Customer Report 20

AE-VMFE
Carbide End Mill for Deep Side Milling

The AE-VMFE carbide end mill is the latest
addition to the AE-VM anti-vibration carbide
end mill series designed to accommodate awide range of milling operations.
The AE-VMFE carbide end mill is engineered
for highly efficient and accurate deep side
milling at L/D of five or more by large step
milling up to 2 x D with its 2.5 x D length ofcut configuration. The AE-VMFE’s long length
reduced shank configuration supports themachining of mold parts with deep side
milling and pocket milling. By changing
the overhand length, the AE-VMFE can
accommodate various machining
depths. Furthermore, withan R shape on the shank side edge, streak
generation can be suppressed by side step
milling. The combination of variable lead,
unequal spacing teeth and microrelief
geometry contributes to this end mill series’
stable and high efficiency milling performance.
The AE-VMFE is available in square and radiusstyles, from diameter 6 to 22 mm, with a totalof 19 items.

Phoenix PDZ
Indexable Flat Drill

The OSG Phoenix PDZ indexable flat drill isengineered to accommodate a wide range ofapplications including drilling, counterboring,
inclined surface drilling, half-hole drilling, andmore. Excellent chip evacuation is achievedby the PDZ’s high precision finishing on theflutes, which improves rigidity, chip ejection
and reduces cutting forces. Moreover, the21 SHAPE IT   Product Pickup

PDZ’s designated insert features an enhanced
muscle breaker with superior chip breaking
ability that enables the tool to excel in drilling,
counterboring and turning applications.

AE-ML-H
Long Carbide End Mill for High-hardness Steels

The AE-ML-H multi-flute square type long
carbide end mill is the latest addition to the
AE-H carbide end mill series for high-hardness
steels. The AE-ML-H features unequal spacing
teeth geometry to suppress chattering duringmachining. Its unique web taper geometry,
where the thickness of core changes from thecutting edge to the shank, greatly improves
tool rigidity and enables highly efficient side
milling even in materials exceeding 60 HRC.
With the addition of OSG’s original DUROREY
coating, the AE-ML-H is able to achieve

high-efficiency and stable milling performancein high-hardness steels due to the coating’s
excellent toughness, high heat resistance andabrasion resistance characteristics.

AE-VTFE-N
Deep Side Milling Carbide End Mill for Non-ferrous Materials

The high performance AE-VTFE-N DLC coatedcarbide end mill is designed for highly efficientand highly accurate deep side milling at L/D of
5 or more. Its 2.5 x D length of cut specification
allows efficient deep side milling with large
step milling of up to 2 x D. The AE-VTFE-N’slong length reduced shank design, where
its outer diameter is larger than the shankdiameter, enables efficient and high quality
deep side milling and pocket milling.
Furthermore, the
AE-VTFE-N’s R shape on
the shank side edge
suppresses thegeneration of streaks due to step milling,enabling high milling quality. With theaddition of OSG’s DLC-IGUSS coating, longtool life can be achieved in non-ferrous metals
such as aluminum alloys that require welding
resistance and lubricity.

SHAPE IT   Product Pickup 22

OSG Offers COVID-19 Vaccine to Employees,
Employee Families and Members ofAffiliate Companies
In 2021, OSG Corporation completed administrating
the vaccination of approximately 2,300 employees,
employee families and members of affiliate companies
in response to the Japanese government’s workplacevaccination initiative.
Severe acute respiratory syndrome coronavirus 2
is the causative agent of the ongoing coronavirus
disease pandemic, which is posing a threat to peopleof every generation. To prevent the risk of infection,
development of severe conditions and to help revive
economic activity, several thousand doses of theModerna COVID-19 vaccine are provided by OSG toworkers, family members and individuals from affiliatecompanies who elect to receive the vaccine.
OSG’s vaccination program is managed by thecompany’s in-house physicians and nurses in an
efficient and safe manner. First and second shots ofthe vaccine have been administrated on multiple
days across two locations at the OSG Guest House in
Toyokawa and Shinshiro Factory in Shinshiro in Aichi
Prefecture during the summer of 2021. A booster shot
(3rd dose) of the vaccine is scheduled to be provided
during the first half of 2022.

1

An OSG employee receives his second shot of the coronavirus
vaccine on August 18, 2021.

2

3

1. Vials of the Moderna COVID-19 vaccine are kept at a designated freezer with temperature
control.
2. The OSG Guest House in Toyokawa, Aichi Prefecture.
3. OSG’s Shinshiro Factory in Shinshiro, Aichi Prefecture.
4

23 SHAPE IT   OSG News

4. OSG Corporation offers COVID-19 vaccine to its workers, family members and individuals fromaffiliate companies in response to the Japanese government’s workplace vaccination initiative.

OSG participates at MECT 2021

OSG staff gathered for a group photograph before the start of MECT 2021 at the Port Messe Nagoya in Aichi, Japan.

Mechatronics Technology Japan (MECT) is the biggest machine
tool exhibition in Japan during odd-numbered years. It is heldin the autumn every two years in Nagoya. The 2021 show took
place from October 20 to 23 at the Port Messe Nagoya in Aichi,
Japan, and had approximately 70,000 visitors. At MECT 2021,
OSG introduced its latest A Brand flagship products, applicationand material specific solutions, and more.
OSG staff pose for a photograph at the company booth’s
reception area.

1

2

1. Displays of some of OSG’s latest tooling solutions for non-ferrous metals.
2. OSG’s latest A Brand products were displayed at MECT 2021 at Port Messe Nagoya during October 20 to 23, 2021.

SHAPE IT   OSG News 24

OSG Around the World
Employee Interview withKatie Kitamura
Tell us about your work and experience at OSG.
I joined OSG Corporation’s sales division in central Japan after
graduating from Aichi University majoring in international
communication in 2015. When I started my professional career,
it was always a dream of mine to work abroad. My inspiration
came from observing my brother leaving Japan to attend
college in the United States for a semester. After working at
OSG for four years, I wanted to gain experiences outside ofJapan – my comfort zone. I consulted with my manager
over a period of time regarding my career goals. Whena position opened up at OSG USA in June 2019, I didn’t
hesitate to say “yes” and have been working as anaccount manager in the United States ever since.
When I reflect back on my professional career, I am
happy to say that I have already achieved some of mygoals. I wanted to be a positive role model to other
women in Japan and show them that women can also
be successful in a male dominated profession and that it
is even possible to do this job outside of Japan.

ProfileLocation: USA
Position: Account Manager
Joined OSG: 2015
Motto: “Nothing is impossible”

Tell us about your daily routine.
My sales territories include Southeast North Carolina, South Carolina, Georgia, and Alabama. As an accountmanager, I would have frequent onsite customer visits with our applications engineers to further optimize
production, tool selection, as well as to provide new production proposals.
What is most challenging about your work?
The most challenging part of my work is having technical discussions with customers and trying to understandsouthern American accent.
What is unique about OSG USA?
Unlike our headquarters in Japan, OSG USA does not have sales offices. Account managers and sales representatives
usually work from their home offices covering an assigned region. However, despite the distance, there is great
chemistry among the different departments, and we always have the support needed in order to deliver the best
possible results for our clients.

25 SHAPE IT   Meet OSG

Kitamura poses for a photograph with a client in the United States. After working at OSG Corporation in Japan for four years, Kitamura
was assigned to OSG USA to serve as account manager in June, 2019.

What is your favorite OSG tool?
My favorite OSG tool is the ADO coolant-through carbide drill series. Our customers love this series because the
ADO offers high performance in a wide range of work materials and applications.
ADO Series
OSG’s ADO is a high performance and versatile coolant-through carbide drill series available in sizes
from 3xD up to 50xD. This series is recently revamped with a new R Gash geometry, which 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 newfeature, the curling of chips is controlled, and the consistency of chip shape has significantly improved toallow superior chip separation versus the conventional design to better meet today’s demand of higher
stability, efficiency, longer tool life, and greater precision machining.

How do you spend time on your day off?
I recently discovered a new sport – pickleball, which combines many elements of badminton, tennis, and table
tennis. I also play volleyball once a week. I enjoy meeting new people and making friends. I currently live close to
the mountains and would spend time to explore during time off. I have uncovered several cozy wineries, hiked to a
few waterfalls, and enjoyed some incredible meals.

12

1. On her time off work, Kitamura enjoys playing volleyball.
2. Far right, Kitamura poses for a photograph with friends at a birthday dinner in Greenville, South Carolina, United States.

SHAPE IT   Meet OSG 26