OSG Global Tooling Magazine

SUMMER 2020

Collaboration
Based on Trust
The right tool, the right priceand fast delivery
Technical Insight

ADO-MICRO Small
Diameter
Coolant-ThroughCarbide Drill

Customer Report

Forgotten Britain in
Good ShapeOSG supports the manufacturing scene
in the UK by providing leading cutting
tool technologies to the advanced andcompetitive British engineering industry
Meet OSG

Employee Interview
in JapanPursuing Growth in a Volatile Market
A Message from the President
The year 2020 marks a major challenge for the world
economy. I sincerely hope that by the time of thispublication, the coronavirus pandemic has subsided.
Market conditions have been hostile to most industries
this year. The cutting tool sector is no exception.
Following a management policy with an aim to double
sales is presumed to be a great challenge under
the current economic environment. In a reduced
marketplace, many companies are feeling the pressure
to take actions to drive sales and may find their efforts
to be insignificant. However, rather than focusing onsales, the emphasis should be on increasing market
share. During times of uncertainties, companies should
refocus on operations and making improvements tothe core of its business. Market share can be increased
through innovations – with new technologies
and products; and the strengthening of customer
relationships – by shortening delivery time, enhancing
customer services, etc. With these key differentiators,
higher values can be delivered, which can ultimately
lead to greater market share.
Volatility doesn’t last forever. OSG will continue its
journey of market growth by continuous improvement
and innovation to provide high value solutions to
manufacturers around the world.

Norio Ishikawa
President & CEO of OSG Corporation

1

SHAPE IT   ﻿CONTENTS Feature
SHAPE ITSUMMER 2020

3 Collaboration Based on Trust

Technical Insight
7 ADO-MICRO Small Diameter Coolant-Through Carbide Drill

Customer Report
11 Forgotten Britain in Good Shape
13 Longer Tool Life with Shorter Run Time
17 The Ultimate Counterbore Solution

Product Pickup
21 SynchroMaster Next Generation Synchronized Tap Holder, Phoenix PD
Comprehensive Indexable Drill Series

22 XPF High Performance Forming Tap, AE-VMS Anti-Vibration Carbide End Mill Series

OSG News
23 OSG Mergers and Acquisitions in Europe

Meet OSG
25 Employee Interview in JapanSHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: July 2020
Rights: Reproduction of the articles and photographs without permission is strictly prohibited.

OSG Corporation International Headquarters
3-22 Honnogahara, Toyokawa, Aichi 442-8543, Japan Tel: (81) 533-82-3288 Fax: (81) 533-82-1132 www.osg.co.jp

SHAPE IT   ﻿

2

From left to right, Prodtek owners Ulf Lepik and Jakob Fornander pose for a photograph with a machined clutch housing made for a bus.
Other complex products from Prodtek’s production can be seen in the background.

Collaboration Basedon Trust
The right tool, the right price and fast delivery
Peter Cramer
OSG Scandinavia
On a Tuesday morning, cheerful conversations can beheard around the table in the city of Lund in southern
Sweden. It is evident that OSG Key Account Manager
Mats Andersson and the owners of Prodtek, Jakob
Fornander and Ulf Lepik, have an excellent relationship.
They chat about their common history, old colleges,
workplace and current tasks at hand. It is a small worldin the manufacturing industry. Andersson, Fornander
and Lepik have known each other for many years. In fact,
Prodtek was one of the first customers that Andersson
acquired after OSG Scandinavia was founded in 2000, andhe became the first of the company’s staff in Sweden.
Prodtek is short for Produktionsteknik in Lund. The
company was founded in 2003 by Fornander and Lepik.

3

SHAPE IT   Feature

The pair started the company from scratch with anempty room. Today, Prodtek employs 18 staff and has
an impressive turnover of approximately 40 million
Swedish krona. Prodtek has now expanded with yet
another production unit located in Ystad, some 70 km
south of Lund.
“I live in Ystad,” says Fornander. “For us and many othercompanies in the area, finding qualified labor is achallenge. Therefore, it makes sense for us to have two
production sites so that we are close to our employees.
And despite the distance, there is good synergy
between our units,” Fornander explains.

Prodtek owner Ulf Lepik processes an item in one of the 11 Mikron machining centers at the company’s manufacturing facility. At Prodtek,
the owners operate the machines themselves.

Prodtek has a total of 11 units of Mikron 5-axis
machining centers, a couple of spark erosion machines,
lathes and a measuring machine. Frequently processedmaterials include aluminum, stainless steel, tool steel up
to 60 HRC, and plastic. The most commonly used cutting
tools are OSG’s AERO end mill series, the A Brand AE end
mill series, the WXS and WXL series, and the EPL series.
“We make prototypes for clutch housings for the
automotive industry,” says Lepik as he shows off oneof their manufactured items. “This is a clutch housing
for a bus that is made out of a solid block of aluminum.
When approved by the customer, it is subsequently
manufactured by casting and then machined. We also
make ready-made clutch housings for cars in the luxury
segment. In these cases, the quantities are often so smallthat they are made of solid aluminum,” Lepik explains.
It all started with molding tools for the packaging
industry, with TetraPak as Prodtek’s customer. “Molding
tool for the packaging industry is still a large part ofour production, and it will continue to be, as packaging

requirements are becoming more stringent due to theincreased focus on climate change,” says Fornander.
“Therefore, we must come up with new solutions thatminimize the use of plastic or use it in a smarter way. But
we also do serial production, so we produce anythingfrom 1 to 10,000 items.”

The AERO-ETS is a part of OSG’s
AERO end mill series for high-speed
milling in aluminum alloys. The
AERO series is perfect for high-power
equipment over 80kW. It is designed
to maximize the full potential of highperformance equipment. The AERO series
is most ideal for high-efficiency processing oflarge aluminum components.

SHAPE IT   Feature

4

From left to right, Prodtek owners Jakob Fornander, Ulf Lepik and OSG Key Account Manager Mats Andersson pose for a photograph at
Produktionsteknik in Lund, Sweden.

“We have no CFO and no receptionist,” Fornander
continues. “We manage everything ourselves, and we
also operate the machines ourselves. All employees areon the same level, and we all participate in the process,from raw material selection to finished products. All
operators program, run the programs and carry out final
checks in the machines themselves.”

product portfolio of high-end tools. Another important
issue for us is that, when we order a tool, we need tohave it delivered the next day. We get all this from OSG.”

Lepik joins in and adds that “the fact that every
employee has full responsibility for an item ensureshigh product quality and is a major part of our success.
It creates cohesion and an inspiring atmosphere in our
everyday work.”“Therefore, we also depend on our suppliers,” Fornandersays. “In the cutting tool business, it is crucial for us tohave a contact who understands our production andour needs. We do not have the time to start from scratch
every time and discuss quality and price. We choose asupplier based on trust – we trust that they understandour needs, and we trust that we are provided the righttools at the right price from a supplier with a broad

5

SHAPE IT   Feature

A dia. 16 R1 AERO-ETS 3-flute carbide end mill is being used at a
cutting speed of 16,000 min-1 and a feed of 6,000 mm/min at a
depth of cut of ap 4. OSG’s AERO-ETS is one of the preferred tools formilling aluminum at Prodtek.

Established in 2000, OSG Scandinavia A/S serves manufacturers in northern Europe, including Denmark, Norway, Sweden and Finland. The
company is led by Director Peter Jørgensen since 2011 and currently employs 18 staff.

About OSG Scandinavia
The Company Thrane Tools, located 30 km west of
Copenhagen in Denmark, was founded in 1974 by Poul
Thrane. In year 2000, Thrane Tools was aquired by OSG
after having been a dealer of OSG tools for several years,
and was renamed OSG Scandinavia A/S.
Today, OSG Scandinavia A/S serves manufacturers
in northern Europe, including Denmark, Norway,
Sweden and Finland. The company is led by Director
Peter Jørgensen since 2011 and currently employs 18
staff. Sales and technical support for manufacturers inDenmark and Sweden are provided by external salesmen
from the Denmark office. There are five salesmen in both
Denmark and Sweden. Norway and Finland are coveredby respected dealers for many years.
Over 150,000 items are available in the Danish stock, withmore being supplied by the European stock in Belgium.
With inventory from both locations, OSG Scandinavia
A/S is able to ship products on a daily basis for next day
delivery.

12

1. Over 150,000 items are available in the Danish stock, with more
being supplied by the European stock in Belgium. With inventory
from both locations, OSG Scandinavia A/S is able to ship products
on a daily basis for next day delivery.
2. The entrance of OSG Scandinavia A/S’ office in Denmark.

SHAPE IT   Feature

6

ADO-MICRO Small Diam
Coolant-Through Carbid
Stable and high efficiency in small diameter deep-hole applications
Hiroyuki Amano
OSG Corporation Applications Engineer (Drill Development Division)

OSG Corporation has recently released the ADOMICRO – the company’s first small diametercarbide drill with oil holes designed for stable andhigh efficiency drilling in deep-hole applications.
The sense of size upon hearing the phrase “small
diameter” will be understood differently amongusers in the manufacturing industry.
The ADO-MICRO has a lineup of drill diameters from
0.7 mm up to 2 mm for drill lengths of 2xD and 5xD,
and diameter 1 mm to 2 mm for drill lengths of
12xD, 20xD and 30xD. The product name ADOMICRO may seem to be associatedwith the unit prefix micro (µ),
but it was named to simply
imply smallness in size
regardless of the unit.

7

SHAPE IT   Technical Insight

For small diameter drilling, options such as carbide
drills and HSS drills using external coolant areavailable. However, today’s machining needs require
greater stability, higher efficiency and longer life
than ever before. There is no exception in small
diameter deep-hole applications, with growing
needs for coolant-through small diameter drills.

eter
e Drill

ADO-MICRO 12D
ADO-MICRO 20D
ADO-MICRO 30D

ADO-MICRO 5D
ADO-MICRO 2D

Tool Geometry
One of the keys for successful small diameter drillingis trouble-free chip evacuation. As illustrated infigure 1, chips generated at the tip of the tool flowin the direction of the blue arrow. However, if there
is insufficient space in the flute, cutting chips cannot
evacuate smoothly, which causes the drilling accuracy
to deteriorate and increases the probability of tool
breakage. Therefore, by providing a wider flute
specification at the area where the tip of the blue

arrow locates, as depicted in figure 1, cutting chips
are able to be discharged without difficulty, leading tostable machining.

In addition, the ADO-MICRO employs a unique
double margin geometry (as depicted in figure 2) inall sizes to enable stable machining even in deephole applications. In order to ensure the rigidity of
the cutting edge, the margin is set to the minimum
necessary length. However, micro sludges can beeasily accumulated around the outer periphery of
the cutting tool, which is a key cause of abrupt tool
breakage. To resolve this challenge and to achieve
an overall balance, an extended flute configuration isincorporated to provide sufficient exit room as shownin figure 3.

Figure 2. Four support points withthe double margin design

Figure 3. Exit room at end of margin

Figure 1. Extended flute

SHAPE IT   Technical Insight8

Oil HolesThe ADO-MICRO features a straight hollow shank design
where coolant is injected in addition to the two spiral oilhole paths. This configuration increases coolant discharge
from the tool tip. Without the hollow shank configuration,
greater pressure is required in order for the coolant topass through the thin oil hole paths. With the hollow

shank feature, pressure loss is reduced, which increases
the coolant flow volume. As illustrated in figure 4, witha higher coolant flow rate, cutting chips can be more
effectively evacuated, thereby enabling stable machining.

Figure 4. Relationship between shank structure and coolant flow volume
Tool

ADO-MICRO 12D φ1.5

Competitor φ1.5

Hollow

Solid

Hollow Shank
Coolant

Water-Soluble (Internal)

Coolant Pressure

1.5 MPaTime of
Lubricant Supply

60 sec.

ADO-MICRO（ml/min）

70

Coolant Flow Volume
67

60
50
40

Competitor

Hollow Shank

30

18.6

20
10
Visual Reference

0

ADO-MICRO 12D

Competitor

OSG’s Latest Coating Technology: IchAda Coating
Another key element for achieving stable processing
in small diameter deep-hole application is coating
technology. The role of tool coating is to provide wear
resistance and heat resistance to prolong tool life, whichis particularly important to small diameter tooling. As
illustrated in figure 5, the coating surface by conventional

technology is not smooth, which may interfere with theperformance of chip evacuation. OSG’s latest IchAda
coating, on the other hand, provides excellent surface
smoothness in conjunction with high wear resistance andheat resistance to enable small diameter tools to achieve
long tool life by improving adhesion.

Figure 5. Surface of coating

Previous Technology

10μm

New Technology

10μm

IchAda is a registered trademark of OSG Corporation.

9

SHAPE IT   Technical InsightCutting Data
Figure 6 demonstrates a comparison of tool life between
the ADO-MICRO and two other tooling manufacturers’
products in the machining of SCM440. The competitor
drills have chipped or have broken at the initial machining

stage. The ADO-MICRO, on the other hand, was able
to achieve long tool life stably due to its superior chip
evacuation capability by breaking chips into small andmanageable pieces.

Figure 6. Stable and long tool life in SCM440
ADO-MICRO 20D φ2

Tool

Number of Holes0Work Material

SCM440Cutting Speed

50 m/min (7,960 min-1)
557 mm/min (0.07 mm/rev)

Depth of Hole

38 mm (Blind) with pilot hole

MachineADO-MICRO
20D

2,000

Corner Chipping

Extensive chipping on thinning

100 Holes
246 Holes

Breakage, twined chips

131HolesVertical Machining Center (HSK-A40)

Competitor A

1,200 Holes
500 Holes

Competitor B

3 MPa

1,500

1,500 Holes

Competitor A

Water-Soluble (Internal)

Coolant Pressure

1,000

ADO-MICRO
20D

Feed

Coolant

500

Competitor B

The ADO-MICRO demonstrates stable performance even indifficult-to-machine titanium alloy applications. As shown infigure 7, the competitor drill struggled with chip evacuation,
thus requiring step processing. However, with the ADO-MICRO, step processing can be eliminated while achieving
approximately five times the drilling efficiency. The ADOMICRO was still in good shape after doubling the competitor
drill’s tool life, allowing it to be used on other applications.

Figure 7. Efficiency improvement in titanium alloyTool

ADO-MICRO 20D φ1.2

Work Material
Machining
Cutting Speed
Feed
Depth of HoleCoolant
Coolant Pressure
MachineNumber of Holes

Competitor φ1.2

0

Ti-6Al-4V
Non-step Drilling

Step Drilling (0.12 mm step)

35 m/min

200

300

ADO-MICRO
20D

400

500

585 Holes

600

Still Running

10 m/min(2,600 min-1)(9,300 min-1)

167 mm/min(0.02 mm/rev)

100

Approx. 5 times

30 mm/min(0.01 mm/rev)

Competitor

300 Holes Wear

15 mm (Blind) with pilot hole
Water-Soluble (Internal)
2 MPa
Vertical Machining Center (BT30)

The ADO-MICRO’s unique tool geometry and OSG’soriginal IchAda coating allow non-step drilling evenfor deep-hole applications, enabling high processing
efficiency. By eliminating common complication in small
diameter deep-hole drilling, the ADO-MICRO is able toexcel with stable performance in a wide range of work
materials including stainless steel. In addition to standard
stock items, OSG also offers customization services with
tailored solutions for each and every manufacturer’s
specific machining needs.

SHAPE IT   Technical Insight 10

From left, OSG UK Area Manager Neil Lane, OSG UK Engineering Manager Hirozumi Kubo and Clarkwood Engineering Head CNC
Programmer Steven Hall pose for a photograph at Clarkwood Engineering’s manufacturing facility in Wolverhampton, United Kingdom.

Forgotten Britain in Good ShapeOSG supports the manufacturing scene in the UK by providing leading cutting tooltechnologies to the advanced and competitive British engineering industry
Hirozumi Kubo
OSG UK
Today, world engineering topics tend to focus heavily
on countries such as China, the United States, Japan
and Germany. However, companies like Clarkwood
Engineering is proving to us that manufacturing in
Britain is alive and in good shape. Brexit? “You can seethat we are flooded with work and we are not affected
at all,” Clarkwood Engineering Head CNC Programmer
Steven Hall comments.
The United Kingdom has been the number one
manufacturing powerhouse during the 18th century,
and currently ranks 9th in world manufacturing output,
according to a 2015 study by the United Nations
Conference on Trade and Development. There is a goodchance that sometime, somewhere, directly or indirectly,
you already are a benefactor of British products. Having
this statistic in mind, have you ever wondered what a
day-to-day manufacturing scene is like in the UK? Well,
Clarkwood Engineering is one of the representative
subcontracting engineering shops that supports theUnited Kingdom’s competitive engineering industry.
Founded in 1974, Clarkwood Engineering Limited is amanufacturer of high-quality special fasteners for a wide
variety of applications. Its key products include bolts,
nuts, plugs, socket cap screws, turned parts, washers,
and more. Employing 77 staff, Clarkwood Engineering

11 SHAPE IT   Customer Report

is located in the city of Wolverhampton in the United
Kingdom, with an estimate land area of 50,000-squaremeter.
As a company that prides itself on superior quality,
Clarkwood Engineering continually invests in the latest
machinery to enhance accuracy and efficiency. Alongwith being a registered ISO 9001 company, Clarkwood
Engineering has also earned the BSL-3 in the American
Petroleum Institute (API) specifications 20E and 20F,
which is most rigorous bolting specification levelavailable. So how does Clarkwood Engineering achieve
successful sales of their high-end products? This iswhere OSG comes in.

Founded in 1974, Clarkwood Engineering Limited is a manufacturerof high-quality special fasteners for a wide variety of applications
located in Wolverhampton, United Kingdom.

OSG is grateful to play a small part in the manufacturingof Clarkwood Engineering’s successful products. One
of Clarkwood Engineering’s core products consistsof nuts that are specialized for heavy duty subsea
and the petrochemical industry, which the company
has been manufacturing since its foundation. Super
duplex, Inconel and titanium are some of the commonly
employed materials and are notoriously known to behighly abrasive to carbide cutting tools. When OSG
first visited Clarkwood Engineering, the company was
already using premium and expensive cutting tools
from well renown global brands. The company is always
under pressure to increase production output whileachieving cost reduction. Due to quality assurance, OSG
products also rank on the higher spectrum in terms
of price. However, OSG UK Area Manager Neil Lanestraightaway noticed the potential improvements inmany of Clarkwood Engineering’s applications.
The production of nuts made of super duplex (30 HRC)
that requires side milling is one of such application.
The super duplex wears the cutters very quickly
and Clarkwood Engineering was actively seeking to
reduce cost and improve cycle time. The company was
originally using a competitor 4-flute carbide end millthat was approximately 40 percent more expensive than
OSG’s UVX-Ti 5-flute cutter.

1

The UVX-Ti carbide end mill series is one of OSG’s latest
milling innovations designed to excel in titanium alloy
applications. It features unequal spacing and variable
lead geometry to suppress chattering. With its optimal
flute shape, smooth evacuation of cutting chips can beachieved at ease. The end mill’s web taper geometry
further enhances rigidity to allow high-efficiency milling.
The UVX-Ti series is available in 4-flute, 5-flute and longstyle configuration.
The competitor tool was able to complete 500 parts
at a material removal rate (MRR) of 25 cm3 / min on aMori Seiki VMC40 vertical machining center. During the
cutting trial, OSG’s 16 mm diameter UVX-Ti was able tocomplete more than 700 parts with a 53 cm3 / min MRR.
By matching the tool life alone would have already madethe UVX-Ti more superior than the competitor tool basedon cost. Not only did the UVX-Ti nearly doubled the tool
life and production output against the competitor tool, italso doubled the MRR to enable an even faster cycle time.
A few months later, Clarkwood Engineering CEO Roger
Wood showed OSG UK Area Manager Neil Lane the cutter
bill and commented that “the UVX-Ti has blown the othertools away, both on cycle time and price.”
Today, Clarkwood Engineering employs OSG products
for a majority of the machining processes required in the
production of various nuts, such as the OSG Phoenix PD
indexable drill for holes, the AT-1 one pass thread millfor thread milling, and the OSG Phoenix PSTW 6-cornershoulder milling cutter for the face milling of large nuts.
All of these tooling are provided with sincere intention
to add values for local manufacturers and the high-end
British engineering sector.

A nut made of super duplex(30 HRC) that requires
side milling. Clarkwood
Engineering’s key
products include bolts,
nuts, plugs, socket cap
screws, turned parts,
washers, and more.

2

1. OSG’s UVX-Ti variable lead carbide end mill enables faster cycle andlonger tool life in Clarkwood Engineering’s super duplex milling application.
2. Today, Clarkwood Engineering employs OSG products for amajority of the machining processes required in the production ofvarious nuts. For face milling of large nuts, the company uses the
OSG Phoenix PSTW 6-corner shoulder milling cutter.

The UVX-Ti carbide end
mill series is one of
OSG’s latest millinginnovations designed
to excel in titanium
alloy applications.

SHAPE IT   Customer Report 12

From left, OSG Sulamericana Applications Technician Gabriel Fernando Gialorenço explains the features of the A-Tap to IMSC Process
Engineer Wilson Santos.

Longer Tool Life
with Shorter Run Time
A-Tap A-OIL-SFT boosts productivity in axle production
Marcela Rattin Bombini
OSG Sulamericana
Founded in 1960, Indústria Mecânica São Carlos(IMSC) is a leading solution provider for the machining
and assembly of parts for the automotive and heavy
industries in markets of Brazil and abroad. Some of its
key products include transmission housings machinedin aluminum and cast iron; axles machined in castiron and rolled or forged steel with or without heat
treatment; and assembly of wheel reduction assemblies
and brake pads.
Employing 188 staff, IMSC’s manufacturing plant islocated in the city of Elias Fausto, São Paulo, Brazil, withan estimate land area of 400,000-square-meter and an
industrial warehouse of 12,000-square-meter.

13 SHAPE IT   Customer Report

Recently, IMSC was looking to improve tool performanceon its axle production made for dump trucks, which thecompany has been manufacturing for about 10 years.
IMSC’s goal was to increase the number of fabricatedparts per tool while decreasing machine time. The axles
are made of steel 39MnCrB6 (350 HB) and has an annual
estimate production volume of 78,000 pieces. Two blindholes at a depth of 54 mm are required to be threaded
per workpiece with a tap tolerance of 6HX. The parts
are machined using an Okuma MA600HB horizontal
machining center and a DMG Mori NH 600 horizontal
machining center.

During a visit to IMSC’s facility, OSG Sulamericana
Applications Technician Gabriel Fernando Gialorenço
requested a tool trial opportunity to tackle the challengeof production improvement. Upon a detail evaluation of
the application, Gialorenço recommended the A-OIL-SFT
M22 x 1.5 DIN 374 (EDP# 48139240 with oil holes added)
from the A-Tap series.
OSG’s A-Tap is an all-purpose tap series designed
to simplify tool management and to excel in a wide
variety of materials and applications. Achieving
trouble-free chip evacuation with a spiral tap in blindholes is particularly challenging and is a main causeof headaches for many manufacturers. To resolve thisproblem and to improve the ejection of chips, OSG’s
A-Tap A-SFT has adopted a variable helix flute design,
which encourages stable chip evacuation and reduces
cutting forces. The helix angle changes from thechamfer, where chips are formed, to the flutes, wherechips are evacuated. This unique geometry enables
greater chip control that can help produce tightly
compacted chips for easy ejection from the hole.

IMSC was searching for tap processing improvement in theiraxle production made of 39MnCrB6 (350 HB). Two blindholes at a depth of 54 mm are required to be threaded per
workpiece with a tap tolerance of 6HX.

Founded in 1960, Indústria Mecânica São Carlos (IMSC) is a leading solution provider for the machining and assembly of parts for the
automotive and heavy industries in markets of Brazil and abroad.

SHAPE IT   Customer Report 14

1

2

1. IMSC Process Engineer Wilson Santos prepares for the machining of the axle part.
2. Some of IMSC’s key products include transmission housings machined in aluminum and cast iron; axles machined in cast iron and rolled
or forged steel with or without heat treatment; and assembly of wheel reduction assemblies and brake pads.

To accommodate a wide range of cutting conditions,powdered metal HSS and OSG’s patented V coating havebeen employed in this series to achieve excellent wear
resistance. In addition, to enable high speed machining,
the A-Tap series incorporates a unique cutting-edge
design that emphasizes sharpness. Not only does the
A-Tap series perform well in general steel, it also excels
in difficult-to-machine materials such as stainless steel
and mild steel. The A-Tap is compatible with various
types of machining equipment – from manual machines
to the latest advanced machining centers.
Due to confidentiality reasons, IMSC’s previous toolingchoice cannot be disclosed. However, at the end of
the trial, it was revealed that the A-OIL-SFT is used at a
cutting speed of 11 m/min versus the previous tool’s

15 SHAPE IT   Customer Report

8 m/min. The OSG tool outperforms the competitor
tool in both time and tool life. The A-OIL-SFT is able toincrease tool life by 20 percent and reduce 4 seconds
of machining time per workpiece. With an annual
production volume of 78,000 pieces, this time saving isequivalent to a total of 312,000 seconds, or 5,200 hours.
Any machinist would agree that breaking a tap in apart as one of the final machining operations can bevery costly, with significant impact made to the overall
production and delivery. By implementing OSG’s A-OILSFT, IMSC is able to achieve stable tapping performanceand reduce cost in their axle production to deliver highquality products at competitive pricing to their clients.

3

3. The A-OIL-SFT is able to increase tool life by 20 percent and reduce 4 seconds of machining time per workpiece. With an annual production
volume of 78,000 pieces, this time saving is equivalent to a total of 312,000 seconds, or 5,200 hours.

From left to right, IMSC President Lino
Fracasso, IMSC Purchasing Analyst Juliana
Santana, IMSC Process Engineer Wilson
Santos and OSG Sulamericana Applications
Technician Gabriel Fernando Gialorençopose for a photograph at the IMSC plant inElias Fausto, São Paulo, Brazil.

SHAPE IT   Customer Report 16

The Ultimate
Counterbore Solution
ADF carbide flat drill more than double tool life and efficiency while
enhancing counterbore hole surface quality in bearing production
Tim Holmer
OSG USA
Professional Bearing Service CNC Programmer Travis Lee prepares for the counterboring operation of their bearings made of 1020 steel in
Los Alamitos, California, United States.

Professional Bearing Service Inc. located in Los Alamitos,
California, United States has been reconditioning
and repairing bearings, oil rings and seals for over
40 years. The shop was founded by Ted and Chris
Mandryk, father and son, respectively, with the goal toachieve superiority in the repair and manufacturing of
Babbitt bearings for a wide range of industries, such

17 SHAPE IT   Customer Reportas oil refineries, power plants, electric motor shops,
mills, sewage treatment facilities, and many more.
Professional Bearing Service currently employs 28 staff
at its 12,280-square-feet shop. Many of its workforce arededicated employees with an average tenure of over
15 years.

Since 1978, Professional Bearing Service has been
serving as a full service 24/7 Babbitt bearing repair andmanufacturing leader.
“We sometimes get calls from companies at 2 a.m. or 3
a.m. saying that their equipment is down, and we would
get right to work to either repair or manufacture newparts for them,” said Joe Gonzalez, Professional Bearing
Service CNC Supervisor.
“When a customer’s equipment goes down,
it can cost them several thousands ofdollars per hour in production,”
said Gonzalez. “The capability tosupply clients with immediate
solutions is immensely
important to their production
schedule and financials,” said
Gonzalez.
Over the years, Professional
Bearing Service has evolved
from repairing bearings to
keeping inventory of certain
products to best service their longtime
customers. As Professional Bearing Service
continues to provide superior products to their clients,
they are always in search of new solutions to further
improve processes.

Recently, Professional Bearing Service has been trying
to resolve an issue they have with counterboring.
Professional Bearing Service counterbores approximately
90 percent of the bearings that the company
manufactures. Professional Bearing Service manufacturesapproximately 500 bearings annually. Bearings being
a round product, can present multiple machining
challenges. There are several places in which machining
curved surfaces to a flat is necessary in order to makethese bearings. The counterbore depths that Professional
Bearing Service deals with range from 1.5-inch toover 4-inch. The long reach requirement
makes it a challenge to identify aproductive and effective tool for thejob.
In the past, Professional Bearing
Service used a half-inch 4-fluteend mill to plunge and peck out
material to create flat holes in1020 steel. The end mill’s lengthof cut was 1-inch with an overall
length of 6-inch. The tool was used
at a speed of 2,000 RPM (262 SFM), a
feed rate of 5 IPM (0.0006 IPT) and a peckcycle of every 0.050-inch using a SouthwesternIndustries Trak Machine Tool machining center. The
average tool life was 50 parts with four holes per part,which is equivalent to 200 holes.

Professional Bearing Service manufactures approximately 500 bearings annually. Bearings being
a round product, can present multiple machining challenges. There are several places in whichmachining curved services to a flat is necessary in order to make these bearings. The counterbore
depths that Professional Bearing Service deals with range from 1.5-inch to over 4-inch.

SHAPE IT   Customer Report 18

Professional Bearing Service has been using OSG’s A-Tap
series for tapping deep blind holes to place bolts into
their bearings. Its CNC department has relied on OSG’s
A-Tap line for the past two years with great results thatno other competitor taps are able to achieve. Withhigh confidence in OSG’s tooling performance anda recommendation by Professional Bearing Service’s
tool supplier Pacific Industrial Supply Co., Professional
Bearing Service decided to try out OSG’s latest drillinginnovation for inclined surfaces and counterboring
applications – the ADF carbide flat drill series – to tackle
their counterboring challenge.
Machining a flat hole traditionally required the useof an end mill and a drill. OSG’s ADF carbide flat drill
enables one-step drilling without requiring a starterhole to shorten machining time and simplify tool
management. The ADF’s unique balanced point form
improves precision and minimizes the shifting of thehole position. Its sharp cutting edge geometry results inlow cutting force to minimize burrs even in thin plates.
With a wide chip room configuration, 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.
Upon a detail evaluation of the application, a 2-flute
10.5 mm (0.4134-inch) diameter ADFLS (EDP# 3333050)
from OSG’s ADF flat drill series was put into the spindle.
The ADFLS’s length of cut is 46 mm (1.811-inch) withan overall length of 160 mm (6.3-inch). With OSG’s ADF
flat drill, Professional Bearing Service’s CNC department
is able to run the 1020 steel application in theirSouthwestern Industries Trak Machine Tool machining
center with greater efficiency. The tool is being used ata speed of 2,500 RPM (270 SFM), a feed rate of 10 IPM(0.002 IPT) and a peck cycle of every 0.050-inch.

The ADF is a multi-purpose flat drill seriesengineered for machining inclined surfaces
and counterboring applications. Unlike
conventional drills, the ADF flat drill is capableof creating holes in inclined and contoured
surfaces without requiring a start hole.

19 SHAPE IT   Customer Report

The ADF series is suitable for materials such as carbon
steel, alloy steel, hardened steel, cast iron and evenstainless steel with its recently expanded oil hole typeoffering ADFO. Professional Bearing Service’s bearings
vary in material, but are mostly made of 1020 steel, castiron, or bronze, all of which can be cut by OSG’s ADF
with ease. Professional Bearing hasn’t seen the full tool
life of the ADF yet, but they are extremely positive withthe result the tool has achieved so far. The ADF flat drill
has thus far completed 140 parts (560 holes), which isnearly three times the tool life of the previous toolingchoice, and is still being used in 1020 steel and bronze
applications. Although the ADF drill is approximately

30 percent more expensive than the competitor tool, it
provides more than twice the tool life, reduces 50 to 70
percent of the operation time, and also further enhances
surface quality.
“We have been able to reduce our run time by 50 to70 percent on this operation while also improving thesurface finish on our product,” said Gonzalez. “Our goalat Professional Bearing Service is to provide the very
best products for our customers, along with the shortest
lead times. OSG has helped us at Professional Bearing
Service to achieve our goals.”

SHAPE IT   Customer Report 20

SynchroMaster
Next Generation Synchronized Tap Holder

The SynchroMaster tap holder is designed
to turbocharge tapping performance on
CNC machines with synchronous spindles
by compensating for synchronization errors
during the threading process. High thrust force
and an increase in cutting pressure
are caused by thediscrepancies between calculated feed andactual movement of the tap. The SynchroMastertap holder’s unique micro float unit eliminates
the extra axial forces on the tap to enable
long tool life, stable tapping performance andprecision thread quality.

Phoenix PD
Comprehensive Indexable Drill Series

The Phoenix indexable drill series consists offour length sizes – 2D, 3D, 4D and 5D, designed
for reliable and highly efficient drilling oflarge holes. The high precision finishing of thisseries’ flute surface dramatically improveschip ejection to eliminate common
deep-hole machining problems such as
chip packing, elongation of chips and tool
breakage. Its unique flute design features
both high rigidity and superb chip
evacuation. With an attached breakerto the cutter body, cutting chips can be
broken into small pieces. Thanks to theabove features, high feed machining can be

21 SHAPE IT   Product Pickup

achieved to maximize efficiency even underrigorous 5xD deep-hole drilling.
This series offers a broad insert lineup toaccommodate a wide range of work materials,
such as steels, stainless steels, cast irons,
aluminum alloys and non-ferrous metals. All
inserts incorporate an economical 4-corner
design that can be applied to both the centerand peripheral cutting edge and are applicableto every cutter body in the series to simplify
tool management.

XPF
High Performance Forming Tap

The XPF represents a new evolution in forming
tap technology. This series is engineered togenerate up to 40 percent less torque versus
other forming taps, making it feasible to tap
materials up to 35 HRC and sizes up to M45
in diameter. Its low-torque design allows
for longer tool life at faster speeds. With theaddition of OSG’s proprietary V coating, wear
resistance can be further enhanced. The XPF isavailable with or without coolant holes, and in
standard or long shank style.

AE-VM
Anti-Vibration Carbide End Mill Series

The AE-VM anti-vibration carbide end millseries is designed to attain an all new levelof milling efficiency coupled with superb
finish quality suitable for a variety of milling
applications. The AE-VM’s sharp positive
rake angle geometry significantly reduces
cutting force to minimize tool wear andpotential damage to the workpiece evenunder aggressive cutting conditions. Cutting
vibration is minimized with the AE-VM’sunequal spacing of teeth and variable-leadgeometry. Furthermore, its unique flute form
helps facilitate trouble-free chip evacuation
to enable stable and consistent performance.

With the addition of OSG’s original DUARISE
coating, tool life can be enhanced by its
excellent lubricity, superior friction-resistanceand high oxidation temperature qualities.
Available in square, radius, stub length,
long neck, long flute and long flute withchipbreakers, the AE-VM series is designed
to accommodate a wide range of milling
operations including slotting, side milling,helical milling, contour milling and ramping
in stainless steel, cast iron, carbon steel, alloysteel and hardened steel.

SHAPE IT   Product Pickup 22

OSG Mergers and Acquisitions in Europe
OSG Corporation acquires three European companies and businesses to better accommodate
the shift to EVs and expand new sales channels
OSG Corporation has recently acquired three European
companies and businesses to further expand global
sales channels. As the automotive industry enters amajor reform period with notable technological changes
such as electrification and self-driven capabilities, OSG
will strive to enhance its competitiveness by expanding
business partners and offering a wider selection of
products to accommodate increasing demand in theelectric vehicle (EV) sector.
In Germany, OSG acquired cutting tool manufacturer
BASS on December 18, 2019 and the cold forming
business of machine tool manufacturer MAG on
November 29, 2019. BASS specializes in the designingand manufacturing of special tools in a short period oftime, and is a major tooling provider for leading European
automakers. More than 50 percent of its sales originatesfrom Germany. The decision was made to complement
European automakers with an expanded OSG sales
channel, commented OSG President Norio Ishikawa.

MAG’s tool business includes rolling dies and tool
manufacturing machinery. The company specializes intools for automobile drive shafts that transmit power totires. Steady demand is expected of drive shafts as they
are indispensable parts in general EVs. OSG’s mediumterm goal is to strengthen the existing business inEislingen and to supplement it with additional products
from the global coldforming network. The location,
support team and machinery will continue to remain
at its current location in Eislingen, Germany, but areorganized under the new company OSG EX-CELL-OGmbH.
In Italy, OSG acquired diamond tool manufacturer Fiudi
in September 2019. Fiudi is a leading company in thedevelopment and implementation of industrial diamond
tools in automotive, aerospace, electronics, hydraulics,
bioengineering and jewelry. Demand for diamond tools
is expected to rise in the future, as they are commonlyused for the finishing process of metals.

About BASSBASS GmbH & Co. KG is a dynamic,
medium-sized family business basedin Niederstetten, Germany. Since its
foundation in 1947, BASS has beendeveloping, producing and marketinghigh-precision products for industrial,efficient thread production. Companies
worldwide from the automotive andaviation industries, as well as mechanicalengineering and medical technology, relyon leading manufacturing solutions fromBASS.

23 SHAPE IT   OSG News

About MAG Coldforming
Technology
For more than 65 years, MAG Coldforming
Technology stands for high productive
coldforming of splines, threads, oilgrooves, knurls and other similar shapes on
rotatory components. The new company
OSG EX-CELL-O GmbH will continue thissuccessful history and position itself as atechnology partner devoted to innovative
manufacturing solutions. EX-CELL-O’s
product portfolio includes state-of-the-art
CNC spline rolling machines, retooling andretrofits on existing machines. Furthermore,high-precision rack dies, prototyping
and small batch productions are also apart of EX-CELL-O’s technology-oriented
businesses.

About Fiudi
Fiudi was originally founded in 1959 in
Turin, Italy by Ing. Mauro Mantecchini,with the aim of introducing monocrystal
diamond in the local industry. In the early
1970s, the company began manufacturing
tools with PCD (polycrystalline diamond),sensing before the economic boom of themillennium that light alloys and composite
materials would have revolutionized themodern industrial sector. Over the years,
Fiudi has expanded its sales throughout
Italy and has significantly increased its
range of products in both quality andquantity to fulfill market needs.

SHAPE IT   OSG News 24

OSG Around the World
Employee Interview with

Akiko Yamamoto
During her 30-year tenure at OSG
Corporation, Akiko Yamamoto has served
as supervisor of the international sales
department, manager of the global
marketing department, and has recently
been assigned as manager of the corporate
planning department.

Tell us about your work and experience at OSG.
I joined OSG Corporation shortly after graduatingcollege in Nagoya, Japan. For more than 20 years, I
worked in the international sales department, taking
charge of overseas orders, imports and exports. In 2014,
I was assigned to the then newly established global
marketing department as manager, overseeing areas
such as ecommerce, exhibitions, catalog production andbranding. In the next couple of years, through annual
global marketing meetings and a newly constructed
intranet, we are able to better unite our employees fromoverseas to further strengthen the OSG brand globally.
Tell us about your daily routine.
I was recently transferred to the corporate planningdepartment in December 2019. Some of my key
responsibilities include investor relationship, budget
planning, performance management and medium-term
management plan creation. Since this department isvery involved in the company’s management policy,
it requires accurate information management andanalytical skills. There is also an executive assistant teamwithin the corporate planning department. Because
our team often works with company directors andexecutives, we have to be quick and flexible in order toaccommodate their busy schedule.

What is most challenging about your work?
The corporate planning department is an importantsection where management policy of the company isdetermined. Decisions must be made based on data
and facts. Sometimes, however, information required
for judgement can be difficult to obtain. It is crucial tocontinuously improve communications with internaland external stakeholders.
What is unique about OSG’s
global marketing department?
I think OSG’s global marketing
division is still evolving. OSG
has a global network in 33
countries around the world.
Our overseas employees arevery talented and are capable ofmaking great contributions to thegroup with their specialties.
At OSG, our staff have highcommunication skills, which
is a great strength of thecompany, allowing us tolisten, develop and fulfil
evolving customer needs.

Akiko Yamamoto

25 SHAPE IT   Meet OSG

Company Location: Japan
Position: Manager of Corporate Planning
Joined OSG: 1990
Motto: “It’s not about when you do, but how you do it”

Far left, Yamamoto poses for a group photograph with her students at OSG Corporationin Toyokawa, Aichi, Japan. Yamamoto is a certified ikebana instructor and belongs to
the Ohara Ikebana School. She also teaches a class weekly at OSG Corporation to allow
employees to explore and study the art after work.

What is your favorite OSG tool?
My favorite OSG tool is the A-Tap. Among OSG’s tap
product lineup, the A-Tap is one of the most popular
items due to its superior performance and reliability.
I hope that the A-Tap can continue to maintain its
position as the “best choice” for manufacturers aroundthe world.
How do you spend time on your day off?
During time off, I often spend my days on ikebana,which is the Japanese art of flower arrangement. I
began studying ikebana when I started working at OSG,
about 30 years ago. There were times when work was
too busy that I was unable to study. I think I am able to

The A-Tap isknown for its superior
chip evacuation capability.
It is an all-purpose tap series developed toaccommodate a wide variety of materials andmachining environments, helping manufacturers
simplify tool management.

continue because I truly enjoy the art. I am currently acertified ikebana instructor and belong to the Ohara
Ikebana School. A study group is held once a monthand I would be assigned to other branches of the school
in Japan to teach. In addition to Ohara, there are over
1,000 types of schools of ikebana throughout the world
today. Ikebana has opened up a new dimension of life.
It has taught me to appreciate Japanese tradition andculture, and to better understand the characteristics ofaesthetics rooted in Japanese people. Ikebana is an art
requiring patience and discipline. I will continue to learn
as ikebana is a lifelong study.

Yamamoto’s work was on display during OSG Corporation’s annual
new year celebration held at the company guest house in Toyokawa,
Aichi, Japan on January 24, 2020.

SHAPE IT   Meet OSG 26