OSG Global Tooling Magazine

Second Edition 2016

TOPICS• Rise to AMRC Tier 1• The Battle Against Space Debris• Global Customer Reports• Product Pickup

for Aerospace
The number of parts required in the manufacturing of an aircraft isestimated to be around several million, with production typicallyconducted in small lots. In the aerospace sector, large corporations
such as Boeing, Airbus, GE and Rolls-Royce are at the very top of the
pyramid, supported by a supply chain made of medium and small
sized enterprises (job shops).
Regardless of company size, customer communication is always at
the heart of all OSG’s effort. Our global team anticipates, listens andactively reacts to market needs by conducting face-to-face business.
This human interaction not only builds trust, but is also the driving
force behind product development. With our face-to-face sales policy,
OSG is able to accurately identify the pain points of our clients tobetter develop solutions that fulfill those needs.
Aviation is a fast-growing market with strong demand for more air
travel. An increasing number of people are flying, which createsheightened pressure to improve travel safety standards. Aerospace
manufacturers are always in search of better materials andtechnologies to create faster, lighter, safer and more comfortable
aircrafts for commercial aviation. At OSG, we too are constantly on
the move, researching and developing new cutting tool solutions.
2016 is the year of IMTS and JIMTOF (two of the world’s largest
manufacturing technology exhibitions). This edition of SHAPEIT provides sneak previews of some of the new products anddevelopments that we will be showcasing in Chicago and Tokyo. Asidefrom cutting tool manufacturing, OSG has also recently taken on a
new mission to tackle space debris with partner Astroscale, Inc. I hope
you enjoy reading through this Aerospace Edition of SHAPE IT andlearning more about OSG’s latest endeavors to contribute to a moresustainable space environment.

Norio Ishikawa
President of OSG Corporation

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CONTENTS

OSG Global Tooling Magazine

FeaturesOSG News

4 Rise to AMRC Tier 1
8 IDEA OSG 1 Mission

24 OSG Becomes Official

Global Customer Report

25 New Investment &14 Shaping Composite Wings
16 Dream Flight
18 Takeoff for New Heights

		 Sponsor of New Space		 Mission to Tackle Space		Debris13

		Acquisitions

Meet OSG

26 Employee Interview

17

Product Pickup

20 BNC Router
21 HBC Router
22 LHX Diamond Drill
23 PFB Ballnose End Mill20

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SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: August 2016
Rights: Reproduction of the articles and photographs without permission isstrictly prohibited.
OSG Corporation International Headquarters
3-22 Honnogahara, Toyokawa, Aichi 442-8543, Japan
Tel: (81) 533-82-1114 Fax: (81) 533-82-1132
www.osg.co.jp

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FEATURE [part 1]

Rise to AMRC Tier 1

Process support for advanced aircraft parts
For many years, OSG has supplied tools for use in the processing of aircraft parts inJapan, the United States, Canada, Brazil, Europe and other markets. We have built a
reputation as a versatile supplier with wide-ranging expertise and experience in the areaof tools that can process difficult-to-cut materials, such as CFRPs (carbon fiber reinforced
plastics) and titanium oxides. We aim to enhance that reputation further by expanding
our activities at the Advanced Manufacturing Research Centre (AMRC).

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FEATURE [cont.]

Advanced Manufacturing Research Centre (AMRC).
Photo Courtesy: AMRC

AMRC
Established as a partnership by the
British Government, the Universityof Sheffield and private sector
corporations such as Boeing, theAdvanced Manufacturing ResearchCentre is the world’s most advanced
aerospace research facility. Its research
activities encompass numerous fields,
including basic materials research, aswell as machining and casting of CFRPs,
titanium and other materials. Over
80 companies are currently involved
including Boeing, Rolls Royce, Airbus,

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Spirit Aerospace and BAE Systems.

Promotion to AMRC Tier 1
Since joining the AMRC in September
2013, OSG has earned recognition for
its advanced technology and ability towork on a wide range of projects. In
June 2015, it was promoted to AMRC
Tier 1. There are approximately 20 Tier
1 companies, the elite members of theAMRC, while another 60 companies areclassed as general participants at theTier 2 level. OSG is the only Japanese

cutting tool manufacturer to achieve Tier
1 status.
In addition to participation in the AMRC
as a director, an OSG representative
will also attend AMRC technical board
meetings. OSG is determined to fulfill
its role as a Tier 1 member by stationing
engineers at the AMRC and proposing
projects. We will also further refine ouradvanced technology through intensive
participation in various projects.

Enhancing Our
Reputation for
Advanced Technology
CRFPs are used to reduce
the weight of aircraft, suchas the Boeing 787 and theAirbus A350. The typesof CFRPs used and theirprocessing properties vary
according to their locations
in aircraft. As a result, a wide
range of tools is needed
to process these materials
optimally. OSG is building
a solid presence within theAMRC, in part because of theneed for its technology andexperience for important
projects relating to theprocessing of CFRPs andtitanium. Another reason for
OSG’s excellent reputation
is its self-sufficiency in all
related areas, including
materials, tool design andcoatings. Promotion to Tier
1 has dramatically expanded
our opportunities todemonstrate our capabilities
in the aerospace sector. We
will continue to contributeto the growth and success of the global
aerospace industry by monitoring
information about industry trends andapplying that information to productdevelopment.

OSG Academy
The so-called “OSG Brain” where
design, testing, production,
training, and evaluation of thelatest cutting tool technology
take place, is located at the OSG
Academy in Aichi, Japan. Home
to over 40 of the latest CNC
machining centers, along with
OSG rapid prototype grinding
machines, many of the industry’s
most advanced aerospace tools
are developed at this facility.

The OSG Advantage
OSG has a comprehensive
offering of diamond-coatedrouters for all composite milling
and trimming needs. Along withrouters, a diverse line of drilling
products are also available,
providing solutions for thevarious composite laminatesand stack drilling challenges.
All of OSG’s aerospace toolingfeatures metallurgy and cutting
geometries to help increase
productivity, reliability and tool
life while reducing machining
time and scrap. OSG also offersa patented ultra-fine diamondcoating, which is a prerequisite whenmachining composites and provides
a definitive advantage over othercompetitor diamond coated products.

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FEATURE [part 2]

IDEA OSG 1 Mission
OSG sponsors satellite mission to tackle space debris
To create a more sustainable space environment and to further expand the horizons of the manufacturing industry, OSG has
partnered with Astroscale, a Singapore-based startup, to construct the world’s very first in-situ microsatellite “IDEA (In-situ Debris
Environmental Awareness) OSG 1” to contribute to the global effort of cataloging small-size orbital debris and to improve futuremanned and un-manned space missions’ safety.

SPACE DEBRISSpace debris is a combination of manmade objects such as rocket upper
bodies, non-functioning satellites, metalfragments, and more. It is a generalterm that refers to failed space objects,
as well as debris resulting from galactic
explosions and collisions. Including
small objects under 10 cm in size, there
are an estimated 5.8 trillion pieces ofdebris circulating in orbit around theearth.

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Most of the active satellites are situatedat the Low Earth Orbit (LEO) region, and
it is where most of the space debris isfound. Space debris with sizes over 1
cm is tracked by international space
agencies to provide advance warningto spacecraft and satellites for necessary
maneuver in case of a potential collision.
Over 100 million pieces of space debris
under the size of 1 cm, however, arenot currently being monitored. Space
debris travel at high speeds in excess of
7 km per second and can cause severe

damage upon collision with satellites
and space stations. At such speeds, evendebris at the size of 1 cm can carry thesame amount of force as a standard
passenger car on earth, according to
Astroscale CEO Nobu Okada. Microdebris has the potential to inflict lethal
damage to satellites, and yet neither
its distribution nor quantities are
fully known. Because of this, a better
understanding of small-size debris as
well as tracking is required.

Top Left: It is estimated that there are over 5 trillion
pieces of space debris orbiting around the earth,much of which have been man made during spacedevelopment.
Bottom Left: OSG Corporation’s application engineer
Yasuhito Fujii prepares for the machining of the IDEA
OSG 1 satellite’s flange ring.
Top Right: A press conference was held in Toyohashi,
Aici, Japan to kickoff the IDEA OSG 1 mission.
Bottom Right: Based in Singapore, Astroscale CEO Nobu
Okada travels around the world to campaign for thesustainability of outer space.

IDEA OSG 1
As a first step to confronting theincreasing threats of space debris, IDEA
OSG 1 was developed by Astroscale
based on a concept model designed
at the laboratory of Professor Toshiya
Hanada at Kyushu University, Japan.
IDEA OSG 1 is a 20 kg microsatellitethat will collect key information
characterizing small-size debris from
100μm or larger in the LEO’s mostcongested areas.

IDEA OSG 1 measures 38 cm × 38 cm ×60 cm (15 inch x 15 inch x 23.6 inch) andis equipped with two film penetrationtype micro-debris sensors known as“Space Debris Monitors (SDM).” Eachof the monitors has a measurement
surface area of approximately 1,000 cm2that detects impacts of micro-debris inquasi-real-time. Approximately 3,300
conductors 50 μm wide are printed
on the polyimide film of the SDM

sensor unit at 100 μm intervals. Microdebris resulting from collisions will beabsorbed by the IDEA OSG 1 throughthe sensors. This data will be collected
and analyzed to help complete themapping of small-size orbital debris
to prepare for the next stage of debris
removal.

Engineer Profile:

Yasuhito Fujii

OSG Corporation Application Engineer
End Mill Product Development Division“The machining of the flange ring is challenging from the perspective of balance. The morematerial being cut from the product, the less rigid it becomes. Deformation may also occur
as the product is removed from the jig and would throw off the overall accuracy of the part,
leading to it being rejected. Due to these challenges, the choices of tooling, jig design andprocessing methods are utmost critical. The satellite flange ring was a challenging project, but
the process has given me a great deal of inspiration for future product development.”

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FEATURE [cont.]

FEATURE [cont.]

MANUFACTURING FOR SPACEIn the course of space exploration,
mankind has created rockets, satellites
and space stations, but the debris
resulting from putting these innovations
into space is now a large stumbling
block for future development. Moreover,this problem has become increasingly
serious, and it is now understood tobe an impending, grave danger toitems that have become essential to
our everyday lives, such as weather
forecasting, GPS and other services
provided by satellites. It has always
been the goal and desire of OSG to use
manufacturing to contribute to a societythat betters the lives of people aroundthe world. OSG has taken a deep interestin global environmental issues
and was genuinely shocked when it
came to understand the magnitude of
the issues posed by space debris.
Since its founding, OSG has continuously
strived to serve as an organization that
contributes to the happiness of not
only its customers, but to global society
as a whole — a hope represented by
its tagline “shaping your dreams.” In
this current endeavor, the desireof Nobu Okada of Astroscale, theresearch staff and all those engaged indirectly confronting the “issue of spacedebris” made a powerful impression.
OSG decided to sponsor this project,motivated by the ability to contributeto this monumental challenge facing
Astroscale.

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SHAPE ITAs IDEA OSG 1’s main sponsor, OSG
also provides technical support on
the manufacturing of the satellite.
The flange ring of the satellite (which
detaches the satellite from the rocket)
is being manufactured at OSG’s Global
Technology Center in Aichi, Japan.
Eighteen types of cutting tools havebeen used in the machining of theflange ring. As it is connected to therocket body, precision and balance
are most critical. Machining accuracy
was inspected throughout the
manufacturing process to ensure thehighest quality possible.
For many years, OSG has been actively
contributing to global manufacturingindustries including automotive,
aerospace, die/mold, energy,
construction and many others. In
support of Astroscale and its promotionof the IDEA OSG 1 mission, OSG strives
to utilize its know-how to protect theenvironment beyond earth, and in doingso, shape our future generation’s dreams
for space.

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GLOBAL CUSTOMERREPORT

Shaping Composite Wings
BNC router eliminates delamination and uncut fibers
Hakan Erdogan, OSG Turkey

Above: The Z spars are produced in a sophisticated five-axis FOG precision milling machine.
TAI’s NC Engineering Leader Mr. Onur Bahtiyar oversees the production of the composite wing spars.
Left: OSG’s DIA-BNC diamond coated router for composite trimming.

Company Profile
TUSAS-Turkish Aerospace Industries, Inc.
Fethiye Mah. Havacılık Bulvarı
No:17 06980 Akıncı-Kazan/Ankara,
TURKEY
Phone: +90 312 811 18 00 ext. 2792
Web: https://www.tai.com.tr/en

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SHAPE ITAn aircraft’s structure is the resultof numerous assembled parts, suchas the engines, fuselage, wings, tail,landing gear, just to name a few. Manyof these components are made oftitanium, advanced aluminum alloys
and composites. In recent years, inorder to achieve greater fuel efficiency
and reduce operational cost, aircraft
manufacturers have placed greater focus
toward applying carbon fiber reinforced
plastics (CFRP), a light, durable andcorrosion-free material, into aircraft
designs.
In the case of the Airbus A350, both thefuselage and wing structures are madeprimarily of CFRP. According to Airbus,
approximately 70 percent of the A350
airframe is made of composite material
structures, titanium and advanced
aluminum alloys. Composites alone
account for 53 percent.

Z-shape spars that TAI has been
manufacturing since 2012.

The Z spars are produced in a sophisticated five-axis FOG
precision milling machine.

The manufacturing process of a
CFRP wing panel typically involves
multiple steps – molding, tape layup,
stringer integration, vacuum bagging,curing, non-destructive inspection,
machining and assembly, and painting.
Machining tools play a key role towards
the end of the manufacturing process.
With safety in jeopardy, precision andquality are utmost critical.
Located in Ankara, Turkey, the TUSASTurkish Aerospace Industries (TAI) has
been manufacturing the A350 aileronspars, a.k.a. the backbone of the aileron,since 2012. TAI specializes in the design,development, manufacturing andintegration of space systems throughout
Turkey. Its Ankara production plant
covers approximately 5 million square
meters with an industrial facilityof 230,000 square meters. The site
is equipped with some of the mostadvanced, high technology machinerythat enables parts manufacturing,aircraft assembly, flight tests anddelivery for the military and commercial
aviation markets.
The composite wing spar that TAI
produces measure 5.5m in length and

The end cut of OSG’s DIA-BNC router.

0.5m in width. Four of the Z-shaped
both thick and thin laminates. With
spars make up one set of ailerons. A total extremely low cutting forces and fluteof 64 sets of ailerons are manufactured
management, tool life can be greatly
per year. A profile tolerance of +/extended.
0.5mm around the entire edge ofthe part is required. The Z spars are“The OSG nicked router is very
produced in a sophisticated five-axis
special since it has all the versatile
FOG precision milling machine.
characteristics,” said Onur Bahtiyar, NC
Engineering Leader at TAI.” Its ability
Throughout the manufacturing process,to side mill and slot, as well as having
TAI had experienced delamination andmultiple cutting edges on the flute
uncut fibers at the cutting edge, which is length is unlike the compression styleunacceptable for the part. Delamination
tool. OSG’s diamond coating is also theis the splitting of a laminate into layers
best I have seen.”
and can occur at a single hole edge orat both hole openings during milling.
Running the DIA-BNC at the same slot
A diamond coated 12.7mm diameter
milling cutting condition of S 6,000 rpm,
compression router was used for theVf 1,250mmpm with flood coolant androughing operation with unsatisfactoryshrink fit holder (short and long type),
tool life.
no delamination and uncut fibers areobserved after machining unlike what
After attending a machining andwas seen previously.
training conference offered by OSG
Turkey, TAI witnessed the performance“Switching to OSG’s nicked routerof OSG’s DIA-BNC router versus otherenabled us to improve surface quality,”
manufacturers’ routers.
said Bahtiyar. “The elimination ofdelamination is providing us a cost
The DIA-BNC is a patented diamondsavings of €17,920 per year.”coated fine nicked router designed
to excel in high feed CFRP roughing
and finishing, and it can be applied to

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GLOBAL CUSTOMERREPORT

Dream Flight

OSG diamond coating shields tooling from wear in composites
Vis Huang, OSG Shanghai

Company Profile
Boeing Tianjin Composites Co., Ltd.
4566 Hebei Road
Marine Hi-Tech Development Area
Tanggu District, Tianjin, China
Web: www.boeingtianjin.com

The Boeing 787 Dreamliner enteredcommercial service on October 26,
2011, with launch customer All Nippon
Airways. By June 15, 2014, the 787
Dreamliner had already flown more than
100,000 times and had carried more than
20 million passengers all over the world.
If you have taken the 787 Dreamliner tosome places you dreamed of, we thankyou for your support!
Today, more than 350 787 Dreamliners
are flying to destinations around theglobe, with more on the way. The
tremendous success of the Boeing 787

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Dreamliner is based on its excellent
flight performance and low-operatingcost. The long-range, mid-size widebody, twin-engine 787 Dreamliner can
carry a maximum of 290 passengers andtravel as far as 15,750km, which is abouta third of the way around the Earth.
It is also Boeing’s most fuel-efficientairliner, which is the result of being thefirst aircraft to implement composite
materials as the primary material in theairframe. Boeing listed its materials by
weight as 50 percent composite, 20
percent aluminum, 15 percent titanium,
10 percent steel and 5 percent others.

According to Boeing, the lightweight
construction had contributed to the787 Dreamliner’s ability to cut down onfuel consumption by 20 percent versus
previous models, which can decrease
the emission of greenhouse gases to ourenvironment.

the splitting of a laminate into layers. As
the aviation industry holds high quality
and safety standards, these conditions
are unacceptable and manufacturing
requires proper tooling that can do thejob right – on the first try.

Composites are corrosion-resistant, All of OSG’s
In China, Boeing
composite
stiff and strong material composed tooling
Tianjin Composites
Co., Ltd (BTC), aof mixtures of fiber. They have three features
joint venture
metallurgy
times the tensile strength thanof The Boeing
and cutting
Company andgeometries tosteel, yet their density is half ofAviation Industry
help increase
aluminum alloy and is only a fifth of productivity,
Corporation ofChina (AVIC),
reliability andthe weight of steel.
produces
tool life while
components for all of Boeing’s
reducing machining time and scrap.
in-production commercial airplanes,
OSG also offers a patented ultra-fineincluding the 787. Based in Tianjin,
diamond coating, which is a prerequisite
China, BTC is equipped with some of thewhen machining composites andmost advanced aero composite material
provides a definitive advantage overproduction machines and laboratories.
other manufacturers’ diamond coated
It is dedicated to the manufacturing ofproducts.
aerospace composite parts for primarystructure, secondary structure and
OSG’s patented ultra-fine diamondinteriors parts of commercial aircrafts. As coating has a maximum diamond grain
an industry leading tool manufacturer,
size diameter of 2 µm. This strictly
OSG provides cutting tools to thecontrolled diameter allows our coating
aerospace industry, including BTC’s 787
program.

to be super smooth and tools to remain
extremely sharp. OSG also manufactures
all diamond products in-house withabsolute control. The end result is adiamond coated product in which
tool life can be consistently predicted,
rather than having to endure premature
diamond delamination issues.
In China, OSG has the recognition of
AVIC, which can be translated to having
recognition from Chinese aerospace
manufacturers. OSG is not only acompany that simply provides tools, butalso supports the daily lives of people
around the world. Maybe you are notaware of our presence, but we do work
diligently to contribute to society and toshaping your dream flight.

Composites are used on the 787
Dreamliner’s fuselage, wings, tail,doors and the interior. Composites arecorrosion-resistant, stiff and strong
material composed of mixtures offiber. They have three times the tensile
strength than steel, yet their density
is half of aluminum alloy and is only
a fifth of the weight of steel. These
characteristics make composite materials
very popular in the aerospace industry.
Machining composites often involves
a high degree of difficulty becauseof their multilayer properties. Highmaterial strength may also lead toshorter tool life. In addition, poorhole quality is commonly present inaerospace applications because of acondition called delamination, which is

Top Left: OSG ultra-fine diamond coating.
Bottom Left: Competitor diamond coating (industry
standard).
Top Right: OSG ultra-fine diamond coating withsmall grain size.
Bottom Right: Diamond delamination (note: large
grain size).

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GLOBAL CUSTOMERREPORT

Takeoff for New Heights
PSE cutter boosts milling efficiency by over 200%
Haron Garcia, OSG Royco

Aircraft, trains, ships and electricalgenerators all have one thing incommon – they are powered by gas
turbines. A gas turbine, also referred toas a combustion turbine, functions by
converting chemical energy of fuel intomechanical energy for rotary movement.
The spinning motion of the turbine
drives a generator that transforms theenergy into electricity, providing power.
Paradigm Precision’s production facility in Guaymas,
Mexico. Photo courtesy: Paradigm Precision

Company Profile
Paradigm Precision
Industrial Park Roca Fuerte
Guaymas, Sonora Mexico 85457
Phone: +52-622-222-7777
Email: info@ParadigmPrecision.com
Web: http://www.paradigmprecision.
com/

laser services, airflow measurement,
thermal coatings, electrical dischargemachining and precision machining
for the aerospace, land-based power
generation and marine markets. The
company operates 12 locations,spanning seven countries, with morethan 1,900 employees. Paradigm
Precision’s Guaymas, Mexico operation
offers capabilities to machinecomponents
The design of theup to 6 feet in
The PSE was able to complete
gas turbine isdiameter, 3-, 4face milling and side milling on and 5-axis milling,customized basedon purpose so thatturning and wire
the part with a perfect finish.
the most desirable
EDM machines,
Moreover, cycle time was reduced and it specializes
energy form canbe maximized. The
in the production
by almost 3 times...
manufacturing ofof struts / bridges,gas turbines for the aviation industry
fan case, compressor housing and split
commonly involves the processing
cases.
of high hardness materials and tighttolerance requirements.
OSG was approached by Paradigm
Precision’s engineering staff
At Paradigm Precision’s manufacturing
regarding the machining of a turbine
facility in Guaymas, Mexico, thecomponent in Rene 41 (40 HRC) with aproduction of aerospace gas turbine
manufacturing volume of approximately
components takes place on a daily basis. 1,700 parts per month. At the time of
Headquartered in Stuart, Florida, USA,the discussion, Paradigm Precision has
Paradigm Precision is a manufacturer
been working on the part for aboutof complex fabrication and precision
two months on their HAAS horizontal
machined components for gas turbine
machining center and was looking toengines. Its core capabilities include
further reduce cycle time. The size ofeach Rene 41 plate is 70mm x 203mm x

Cutting Conditions
OSG
Vc= 44 m/min
n= 185 rpm
ap= 1.5 mm
ae= 76.2 mm
F= 0.8 mm/rev
fz= 0.1 mm/z
Z= 8Cycle time: 82 sec.

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Competitor Tool
Vc= 40 m/min
n= 205 rpm
ap= 0.75 mm
ae= 76.2 mm
F= 0.3 mm/rev
fz= 0.04 mm/z
Z= 8Cycle Time: 240 sec.

Turbine component plate in Rene 41 (40 HRC) with a dimension of 70mm x
203mm x 25.4mm.

Face milling of the Rene 41 plate in Paradigm Precision’s HAAS horizontal
machining center using blasomill oil as coolant.

25.4mm with a tolerance requirement of+/- 0.3mm. Due to the tight tolerancesand hardness of the material, Paradigm
Precision had to face mill in two steps
with another manufacturer’s tool.
This process required approximately
four minutes of cycle time. Paradigm
Precision at the time already worked
with OSG drills and taps for machining
exotic materials and decided to seek
new solutions for its milling needs as
well.
After a detailed evaluation of theapplication, a 3-inch diameter OSG
Phoenix shoulder cutter end mill PSE(EDP 7801213) with 8 XC5040 inserts(EDP 7816056) were suggested. The PSE
is a versatile indexable series designed
to excel in a variety of cutting conditions.
With its high precision insert and uniqueinsert form, chips are broken into small
pieces, enabling the tool to perform side
milling, slotting, ramping and helicalmilling efficiently.
The PSE was able to complete face
milling and side milling on the part witha perfect finish. Moreover, cycle time
was reduced by almost 3 times from
240 seconds to only 82 seconds using
blasomill oil as coolant on their HAAS

horizontal machining center.
With significant cycle time reduction,
Paradigm Precision is now able toprocess 34 parts per hour versus 12 parts
per hour. Operator hours have also been
greatly reduced to 2.5 hours versus theoriginal 7 hours. Being able to save morethan 4 hours of production time a day
and productivity improvement of over
200%, Paradigm Precision is ready totakeoff for new heights.

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19

PRODUCT PICKUP

DIA-BNC

Diamond coated router forcomposite trimming

The DIA-BNC is a patented diamondcoated fine nicked router designed
for carbon fiber composite trimming.
The router features patented cutting
geometry and OSG diamond coating toeliminate uncut fibers and delamination,
which are common machining problemsof composites. The DIA-BNC excels inhigh feed roughing and finishing andcan be applied to both thick and thinlaminates. With extremely low cutting
force and flute management, tool life
can be greatly extended.

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DIA-HBC

Diamond coated herringbone
router for high feed milling andfinishing in thick laminates

The DIA-HBC is a herringbone stylerouter for high feed rates and excellent
surface finishes in difficult to cut fibers,
honeycomb sandwich materials anduniquely shaped parts. The flagging
of material is a predominant problem
during the machining of honeycomb
structures. The DIA-HBC features acompression cutting design to reduce
the tendency of flagging. This router isengineered to excel in unique geometryparts, specifically when the fiber
orientation changes dramatically.

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PRODUCT PICKUP

AERO-LHX

Diamond coated low helix drill
for composites

The AERO-LHX is a diamond coateddrill designed for tough laminates. It
eliminates uncut fibers and delaminationin applications where other drills areunable to properly cut fibers. The drillfeatures a triple angle geometry to
reduce push-out exit delamination anda low helix design to provide a sharper
cutting edge to shear tough fibers.
Combined with OSG’s patented diamondcoating, the AERO-LHX is able to achieve
excellent performance in tough andunidirectional composites.

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SHAPE ITOSG
PHOENIX® PFB
High precision indexable finish
ballnose end mill

The OSG Phoenix PFB is an indexable
ball end mill ideal for 3-D finishing
operations where precision and surface
finish are critical. It features very highinsert radius precision (+/- 6 µm) toenable superior milling surface finish.
The PFB’s spiral cutting edge enables
excellent strength and sharpness. Its
PVD coated grades are most suitable formilling mold materials for composites.
The PFB’s shank is available in steel or
carbide. The carbide shank is designed
to inhibit chattering and to increase
both precision and tool life, and thesteel shank is targeted for superior cost
performance when working with shorter
projection lengths.

SHAPE IT23

OSG NEWSOSG Becomes Official Sponsor of New Space
Mission to Tackle Space Debris
OSG Corporation held a press
conference on December 15, 2015 at
the Hotel Arc Riche Toyohashi, Aichi,
Japan to announce its sponsorshipwith Astroscale, a Singapore-based
private space company foundedin 2013, on the world’s very firstin-situ micro satellite “IDEA OSG 1”
to collect and monitor data on submillimeter sized debris in the Low
Earth Orbit (LEO) region in real-time.

for new challenges and commitment
to help clients accomplish their goals.
With the new “IDEA OSG 1” mission,
OSG strives to utilize its knowhow and resources to protect theenvironment beyond earth, shaping
the future generation’s dreams forspace exploration.

The mission of the “IDEA OSG 1”
sponsorship aims to contribute to
the sustainable use of the spaceenvironment by actively developing
solutions to prevent space debris.
OSG’s corporate tagline “shaping
your dreams” summarizes its passion

Above: The IDEA OSG 1 press conference was heldat the Hotel Arc Riche Toyohashi in Aichi, Japan
with the attendance of over 50 guests. A special
panel discussion also took place with members
including former astronaut Naoko Yamazaki,
Kyushu University’s Professor Hanada, as well as
renowned Broadway and Kabuki director Amon
Miyamoto.

Left: OSG Corporation’s President Norio Ishikawa
and Astroscale’s CEO Nobu Okada announce the
IDEA OSG 1’s mission during the December 15,
2015 press conference.
24

SHAPE ITOSG Invests in New Carbide Material Factory
OSG maintains absolute control over every aspect of its
manufacturing capabilities. OSG products are produced
in-house – from the production of tool material, to thecreation of tool geometry, to the development of its own
proprietary coatings.
Tool material, which attributes to hardness and toughness,is one of the three vital elements in the manufacturingof superior cutting tools. OSG has been developing andmanufacturing its raw materials with Nihon Hard Material(NHM), a subsidiary company of the OSG group, since 1990.
In order to respond to the increasing carbide product demand
from the aerospace and automotive industries, OSG isinvesting 3 billion yen in NHM to construct a new factory in
Takeo City in Saga Prefecture of Kyushu, Japan, near NHM’s
main manufacturing facility. The new factory is scheduled to
be in full production by the fall of 2016.
Top: A conceptualized image of Nihon Hard
Material’s new factory in Kyushu.
Bottom: OSG’s Oike Factory located in Toyokawa,
Aichi, Japan. New carbide end mills and drills are
manufactured in this facility.

In addition to expanding the production capacity of raw
materials, OSG is also investing over 1 billion yen to enhance
the carbide end mill and drill production capacity of its Oike
Factory in Toyokawa City of Aichi Prefecture.

OSG Acquires Cutting Tool Manufacturers
Desgranges and AMAMCO
OSG has acquired Desgranges Holding S.A.S. of France inlate 2015 and AMAMCO Tool of the United States in April
2016. Established in 1946, Desgranges is a manufacturerof standard and special cutting tools, and supplies tomajor French contractors in civil and military aviation,
automotive and high-tech related sectors. Establishedin 1972, AMAMCO of Duncan, SC, USA specializes in
the manufacturing of carbide cutting tools for major
aerospace, automotive and medical customers. Throughthese new acquisitions, OSG will further facilitate market
growth in the aerospace industry worldwide.

SHAPE IT25

MEET OSG

OSG Around the World
Employee Interview with Todd Surritte

OSG Corporation was founded in 1938, more than 77 years ago. Today OSG holds the No. 1 position in the Japanese cutting tool
market as well as a top-ranking position globally, with a production, sales and technical network spanning 29 countries. Ourcommitment to innovation, services, total solutions and out-of-the-box thinking has contributed to our immense success today.
However, without our employees, none of it would be possible. We truly believe that our employees are one of the greatest assets ofthe company. In this section, we will introduce our team members from around the world.

Upper Left: Todd and his colleagues at the
OSG USA corporate office in Glendale Heights, Ill.

Top: The AERO-BNC router designed for milling composites is manufactured at OSG USA’s Bensenvilleproduction facility. Bottom Left: Todd is a long standing member of the P.R.I.D.E committee.

Tell us about your work &experience in the aerospaceindustry:

have 135 employees and over 50 CNC
grinding machines producing 75,000 to
100,000 pieces of carbide products every
month. We also regrind drills and otherproducts for our customers at this facility.
I am proud to say that OSG has some of
the most high tech tools in the industry
for Aerospace. We have come a long way
since 2000 and are looking forward toleading the way in the future.

I have a Bachelor of Science inAerospace Engineering from the
University of Notre Dame, so I learned
about airplanes while I was in college.
When I became Area Sales Manager in
the Northeast Region back in 2000, I
called on many aerospace companies.
Back then, we did not have as many
CFRP applications like we do today,
so OSG mainly sold taps to thosecustomers. Today, I’m Vice President of
Operation overseeing our Bensenvillemanufacturing plant at OSG USA. We

26

SHAPE IT

What is unique about the US
division at OSG?
OSG USA has a culture called PRIDE
which stands for, people, respect,

integrity, development, and excellence.
We also have a Triple O philosophy of
Outservice, Outsmart and Outfun.

How do you spend time on yourday off?
On my days off, I enjoy spending timewith my children. I have two boys, ages
3 and 8, and a daughter who is 11 years
old. They play soccer, baseball, andsoftball, so we are constantly going topractices or games. When I get somefree time, I like to play a round of golfwith some friends.

What is your favorite OSG
aerospace tool?

Left: The AERO-BNC is a diamond-coated routerdesigned for milling CFRP and other composites.

My favorite OSG aerospace tool is
the AERO-BNC (List 2061), a finenicked router specifically designed
for composite trimming. I like this tool
because we make it here in Bensenville,
Ill., and it is one of the best tools for
CFRP in the whole aerospace market.

OSG USA’s manufacturing facility in Bensenville, Ill..

Todd Surritte
Company Location: OSG USA
Position: Vice President
Joined OSG: 1994
Motto: “There is no I in team”

SHAPE IT27

Did you know?
Approximately 150 million pieces of debris (larger than 1mm)
are orbiting the earth at the speed of 7~8km/sec at an altitude of400~1,000km. This space debris increases the potential danger tothe International Space Station and other spacecraft with humans
aboard.
Visit www.ideaosg1.com to learn more about the threat ofspace debris and the IDEA OSG 1 mission.

Image courtesy of
Astroscale.