FEATURE:
MANUFACTURING EXCELLENCEOSG GLOBAL TOOLING MAGAZINE I SUMMER 2024

OSG cold forming technology supports
prestigious structural bolting firm emerged
from industrial heritage of Sheffield, England

TECHNICAL INSIGHTGLOBAL REPORTS

OSG NEWSEMPLOYEE INTERVIEW

6C x OSG: The new standard
for hard and brittle material
processing

USA
Italy
Denmark
BrazilFusion of Sports& Manufacturingin Poland

Advance to the next stage by breaking
away from static plans and rigid mindsets
A Message from the President
In March 2024, OSG celebrated its 86th anniversary.
OSG has been able to grow to the size it is today by
advocating the company’s management philosophyof having a “global presence” and finding successoverseas under the slogan “economic global
presence.” On the other hand, to achieve continuous
growth in the future, it is critical to break awayfrom static plans and rigid mindsets within thecompany and refresh the attitude of each and every
employee. Last December, in order to respond tovarious changes in the external environment, OSG
revamped the sales structure of its three domestic
sales divisions for the first time in 60 years. Evenin the domestic market where OSG enjoys highmarket share, we are making new strategic steps
to accelerate growth. Furthermore, in anticipationof a future with rising concerns regarding humanresource shortages due to the declining birthrate
and aging population, OSG has designatedthe administration department as a resource
management center with the aim of effectively
utilizing all management resources, including
people, goods, capital and information technology.
Additionally, .ACT Co., Ltd., which is made up of
members who have contributed to OSG 4.0, wasspun off as an in-house venture and became
independent. All of these initiatives are efforts to break away from our comfort zone and to tackle new challenges.
We will continue to foster a comfortable working environment and system while maintaining good labor-management
relations typical of OSG, which has been built over our long history, so that each and every employee can freely
demonstrate their abilities and achieve results. Simultaneously, digital transformation (DX) will be indispensable forstrengthening corporate structures that generate profits by saving labor and improving production efficiency. OSG
will be striving for a hybrid DX that combines high value-added products created by skilled employees with systematic
responses.
Within the company, we are nurturing visualization practices and transparent communication in the workplace, where
employees are empowered to voice their ideas and take on new challenges. 2024 is the final year of Stage 1 of OSG’smedium-term management plan “Beyond the Limit.” Stage 2 will begin in 2025, which will be an important phase forthe future. The entire OSG group will work coherently toward our shared mission, move forward with these efforts, andproduce results to achieve our goals.

Nobuaki Osawa
President & COO of OSG Corporation
1

SHAPE IT   ﻿CONTENTS Feature
SHAPE ITSUMMER 2024

3 Manufacturing ExcellenceTechnical Insight
11 6C x OSG

Customer Report
17 Versatile and Efficient
A-Tap simplifies tool management and accelerates productivity in pump component production

19 Perfect Chip Control Even in Deep HolesVPO-DC-MT cutting tap reduces tapping cycle time and increases tool life in steel bracket code
production for corn heads

21 Clamping Productivity
AE-VML long carbide end mill accelerates performance in clamping system production

23 Tool Consolidation
Custom carbide step drill consolidates machining process and increases tool life in swivel housing
production

Product Pickup
25 A-XPF Forming Tap, ADO-SUS Carbide Drill
26 AE-CRE-H Carbide End Mill, AE-HFE-H Carbide End MillOSG News
27 Fusion of Sports & Manufacturing

Meet OSG
29 Employee Interview in Poland

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: July 2024
Rights: Reproduction of the articles and photographs without permission is strictly prohibited.

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

2

1

Manufacturing
Excellence

OSG cold forming technology supports prestigious structural bolting firm
emerged from industrial heritage of Sheffield, England
Hirozumi Kubo
OSG UK
Cold forming is a high-speed forging process thatplastically deforms metal using dies at near room
temperatures. It is a fast, precise, and automatedprocess that produces large amounts of metalcomponents without removing any material. Unlike
hot working, cold forming shapes metal at cooler

3

SHAPE IT   Featuretemperatures. Because the crystal grains are
unbroken, greater strength-to-weight ratio can beachieved with enhanced mechanical properties,
which contributes to a stronger and more
dependable part. Higher surface finish can also be
obtained as there is no corrosion of workpiece.

2

1. From left, Helix Tool Company Technical Sales Director John Smith, Cooper & Turner Production Manager
Andy Gale, OSG UK Area Sales Manager Phil Ridsdale, OSG UK Engineering Manager Kirk Kubo and OSG UK
Sales Manager Paul Fitton pose for a photograph at Cooper & Turner’s manufacturing facility in Sheffield,
England.
2. External threads have been formed onto the metal bar.

Cold forming requires heavy equipment and is ideal for large volume manufacturing. The initial investment ofcold forming may be expensive up front, but it is able to eliminate or significantly reduce a variety of secondary
operations, which contributes to faster lead time and reduces overall cost.

A wide variety of materials can be cold formed,
such as alloy steels, aluminum, brass, bronze,
copper, nickel alloys, stainless steels, etc. Coldforming can create large components suchas car panels and flat sheets as well as small
parts like screws, nuts and bolts. It is suitablefor diverse industries such as aerospace,automotive, agriculture, construction, energy,transportation, and more. With short cycle time,high energy efficiency and minimal waste, cold
forming is a highly sustainable metalworking
process.

Key Benefits of Cold FormingHigh productivity
High quantity output
Reduces secondary operations
Fewer scraps and waste
Energy-efficient
Cost effective
Good surface finish
Consistent dimensional accuracy
Greater workpiece load capacity
High customizability

SHAPE IT   Feature

4

OSG Cold Forming Solutions
In 1956, OSG began the manufacturing and salesof rolling dies. Today, the company offers a broad
lineup of dies and thread rolling products including
cylindrical dies, flat dies, trim dies, planetary diesand rack dies. OSG is one of the world’s largest
manufacturers of rolling dies, with more than
70,000 cold forming tools being produced annually
through several production sites in Japan, the UnitedStates, Mexico, Germany, China, Taiwan, Korea,
Thailand and India.
Utilizing the same advanced technology the company
uses for its world-renowned taps, OSG manufacturesa variety of dies in accordance with their intended
use with superb precision and tool life. OSG canmanufacture dies based on any desired specifications
and can provide tailored evaluation and solutions.

In 2019, OSG further expanded its product portfolio andemphasis on the European market by acquiring
OSG EX-CELL-O, a German company that specializes
in cold forming machines and tools that serviced theEuropean market for over 65 years. OSG EX-CELL-O offers
highly productive cold forming solutions of involute
splines, threads, oil grooves, knurls or other similar
shapes on rotationally symmetrical components.
The OSG group cooperates intensively to analyze tooltechnology in order to provide the best technicalsolutions to clients in different regions. With a vast
product lineup, years of indispensable know-hows andan extensive global support network, OSG is ready torespond to evolving cold forming needs with innovative
solutions.

OSG manufactures a variety of dies in accordance with their intended use with superb precision and tool life. OSG can manufacture dies
based on any desired specifications and can provide tailored evaluation and solutions.

5

SHAPE IT   Feature

Cooper & Turner Ltd.
Recently, Cooper & Turner Ltd., a manufacturerof high strength and safety critical fasteners, isable to leverage OSG’s cold forming solutionsin its bolt production.
Founded in 1863, Cooper & Turner is a global
leader in the manufacturing and supply of
structural bolting and has a long-standing
reputation for quality products and service. Itsbolts, studs and industrial fasteners meet thestrictest requirements and provide maximum
safety for operating in some of the world’s
most hostile environments - from the heatof the deserts, the cold of the Arctic, to thedeepest of seas.

1

2

1. Stacks of threaded parts. Cooper & Turner is a global leader in the manufacturing and supply of structural bolting and has a long-standing
reputation for quality products and service.
2. Cooper & Turner’s production plant in Sheffield, England, United Kingdom. Founded since 1863, Cooper & Turner has over a century ofacquired knowledge and experience in high strength and safety critical fasteners.

SHAPE IT   Feature

6

Stocks of metal blanks (round bars).

Cooper & Turner’s global headquarters is locatedin Sheffield, South Yorkshire, England. Sheffield
is a historical city that strived and flourished withsteelmaking dating back to the 16th century.
Sheffield’s unique geography offered optimal
steelmaking conditions - the hills suppliedcoal, iron and millstone grit for the workshops’
grinding wheels; the city’s seven rivers provided
waterpower (in the days before steam); its forests
were the sources for wood and charcoal. And mostimportantly, Sheffield became the birthplace of
manufacturing innovations such as crucible steel

7

SHAPE IT   Feature(cast steel) and stainless steel, which continue todominate the world’s steel industry for years tocome. Cooper & Turner emerged alongside thishistory.
Since its foundation in the 1800s, Cooper & Turnercontinuously contributes to the fastener industry,
supplying high strength friction grip fasteners,
including ground-breaking inventions and patentssuch as the “Coronet Direct Tension Indicator,” aproduct that ensures correct torque tensioning forhigh strength bolting assemblies.

A cold forming machine at
Cooper & Turner’s production plant in
Sheffield, England.

Some of the markets that Cooper & Turner services
include renewable energy, oil and gas, construction,rail, tunnelling, petrochemical, and subsea. Cooper& Turner’s strategic operations in Europe, Asia Pacificand the United States allow the company to support
customers on a global basis.

Cooper & Turner’s production plant in Sheffield has
an estimate land area of 35,000-square-meter. Its
extensive manufacturing facilities with both hot andcold forging capabilities enable the company to supply
a wide range of products in various sizes.

Thread rolling is a widely applicable method
for mass production of fasteners, using theplasticity of metals to form the external
threads onto metal blanks (round bars), byroll feeding the bar between two or several
sets of rolling dies.

SHAPE IT   Feature8

A threaded metal bar.

Over decades of fastener making, Cooper & Turner has progressed from various styles of thread making to rolling
dies, achieving requirements in both quality and quantity. Thread rolling is a widely applicable method for mass
production of fasteners, using the plasticity of metals to form the external threads onto metal blanks (round bars),by roll feeding the bar between two or several sets of rolling dies. This method enables high volume production
at a typical rate of 10 to 1,500 parts/min with high precision and minimum variation. Unlike milled threads, highquality surface finish is maintained across long production shifts. Moreover, uncut fiber flow makes approximately
20 percent stronger threads. Therefore, the quality of rolling dies has been a vital importance to Cooper & Turner tobe at the top of the game.

OSG UK Area Sales Manager Phil Ridsdale and Helix Tool
Company Limited (Helix), a top tier OSG distributor, havebeen in touch with Cooper & Turner for many years seeking
for new business opportunities in rolling dies. OSG firstsupplied flat die samples in 2017 and the rest is all successstories. Today, OSG supplies more than 12 sizes of various
dies, ranging from M30 to M72, with more opportunities on
the scope. There is twofold to what made OSG rolling dies
stand out for Cooper & Turner to change. One is the mostobvious defining factor: tool life. Back in 2017, the first
M30 sample supplied achieved over 12,000 bars comparedto 6,000 bars by the competitor dies. OSG dies, although
10 to 15 percent more expensive, performed to improve
cost per unit over 50 percent as well as massively reducing
machine downtime.

9

SHAPE IT   Feature

An OSG M42 x 4.5 cylindrical die. Cylindrical dies are
ideal for a wide range of precision threaded parts. Threadrolling cylindrical dies are used in set of two or set ofthree. OSG offers customization in accordance with any
desired specification.

The second factor is OSG’s technicalexpertise and reliable support network.
Before OSG became the main die
supplier at Cooper & Turner, there had
been times where OSG went aboveand beyond to deliver solutions. Oneof the times was when OSG went as far
as to inspect the machine and material
settings to resolve issues that machinedbolts were not gauging correctly andwas halting production output alreadyunder pressure. Having provided fullinspection report on the tools (dies)to cancel out the possibility of faulty
dies, investigation led OSG to discoverthat the material bar sizes were outof tolerance in disparity, leaving notenough volume of material to be rolled
and achieve pitch diameter and major
diameter of the threads required.

Stocks of OSG rolling dies. OSG supplies more than 12 sizesof various dies, ranging from M30 to M72, toCooper & Turner.

Helix Tool Supply Management
Helix Tool Company Limited was established in 1994 in the heart of Yorkshire in
Northern England and has been OSG’s technical supply partner for over
25 years. Tool Supply Management (TSM), one of Helix’s latest inventory tracking
solutions, is a vending machine that is engineered to maintain accurate inventory,
enable short delivery, and simplify report as well as invoicing for its users.

As this case demonstrates, depth of knowledge on not
only tools but surrounding factors and the utilization ofscientific approach are the strength of OSG’s technicalsupport. Last but not the least, Helix, OSG’s technicalsupply partner for over 25 years, has been an immensepart of maintaining stability in the supply chain;
Tool Supply Management (TSM), one of Helix’s latest
inventory tracking solutions, is a vending machine thatis engineered to maintain accurate inventory, enable
short delivery, and simplify report as well as invoicing
for its users. With the proximity of its Sheffield branch to
Cooper & Turners, Helix enables precise communication
between both OSG and Cooper & Turners, by grasping
accurate information in a timely manner pertaining
stock, delivery, technical or commercial issues - all ofwhich, added values to the customer experience.

Product quality is of paramount importance to Cooper & Turner as its products are safety critical and must function
in some of the most rigorous environments. With unique metallurgy, design methods and surface treatment
technologies to improve productivity, accuracy and tool life, OSG will continue to go beyond the limit to support
Cooper & Turner in its pursuit of manufacturing excellence.

SHAPE IT   Feature 10

6C x OSG
The new standard for hard and brittle material processing
Hirofumi Inayoshi
OSG Corporation

Hard & Brittle Materials
Hard and brittle materials such as cemented carbide,
ceramics and quartz glass offer incredible wear resistanceand heat resistance. With material properties that cannot
be met by metal or plastic-based materials, hard materials
are increasingly applied in a wide range of industries suchas automotive, mechatronics, chemical, medical, aerospace,and more. The use of cemented carbide, ceramics and quartz
glass in particular has elevated year by year in the mold andsemiconductor sectors to improve precision and durability ofcomponents.
Although hard materials are ideal for many applications, they
can be weak against impact and can break unpredictably
due to their brittle characteristic. In addition, the processingof hard materials is highly challenging, requires a lot oftime, and the tools used are subject to severe wear,
making it an expensive production process. High
tool wear and ensuring that the required level ofprecision is met while keeping machining cost
low are some of the common obstacles ofprocessing hard and brittle materials.
Grinding has been the standard
technology used for machining hardand brittle materials. For materials
that are electrically conductive,
electrical discharge machining(EDM) is also used. Thesemethods, however, often
require long cycle timeand many processing
steps.

11 SHAPE IT   Technical Insight6C x OSGTo enhance cost efficiency in the processing of hard andbrittle materials, OSG Corporation has partnered with 6C
Tools AG in 2022 and established the 6C x OSG brand.
Founded in 2015, 6C Tools AG (6C) is a tool manufacturer
based in Zurich, Switzerland. 6C, which manufactures
cutting tools using solid polycrystalline diamond (PCD) as abase material, is a startup company that supplies products
to precision processing manufacturers in Switzerland andabroad.
Established in 1938, OSG Corporation is one of the world’s
leading comprehensive cutting tool manufacturers. 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 more than
30 countries. OSG’s world-class R&D facilities andlaboratories are staffed by highly trained engineers, alldedicated to developing the highest quality products using
environmentally friendly processes. OSG has traditionally
maintained a powerful marketing presence in manufacturingindustries including automotive, aerospace and mold anddie. OSG also supplies products to energy-related industries,
the construction equipment industry, as well as to the
manufacturers of micro precision equipment that requires
high machining accuracy, such as semiconductors for 5G,
precision molds, mobility, and robotics.

SHAPE IT   Technical Insight 12

6C x OSG is a cutting tool series optimized for the processing of hard and brittle materials with high precision and good surface finish
at a new level of geometric complexity. The 6C x OSG brand proposes a new concept for machining free-form shapes out of hard, brittle
materials without the drawbacks of both grinding and EDM. PCD tools by 6C x OSG enable direct machining that is highly efficient andaccurate, which shortens machining time, reduces costs, minimizes energy consumption, and contributes to the realization of carbon
neutrality.

Product Overview
PCD Drill “PCD-MXD”
The PCD-MXD is composed of solid PCD engineered for long tool life in the drilling of hard and brittle materials.
Its unique w angle geometry prevents chipping on the tool and workpiece. Furthermore, its low helix flute form
improves tool rigidity, making it ideal for machining hard and brittle materials such as cemented carbide,
ceramics and quartz glass.

120th hole shows good quality.

Cutting edge condition after drilling 120 holes.

Machining Example

120th hole
shows
good
quality.
The average tool life of a conventional diamondcoateddrill
in siliconcarbide is around
30 holes. As depicted in figure 1, the PCD-MXD demonstrates superior tool life by completing
120condition
holes
Cutting edge
after drilling 120 holes.
with a single tool in silicon carbide and can continued to be used.

120th
120th
hole
hole
shows
shows
good
good
quality.
quality.
Cutting
Cuttingedge
edge
condition
condition
after
after
drilling
drilling
120
120
holes.
holes.

Process

Process

Tool

Process
Process
Tool

NumberTool Size

Cutting Speed) Step(min -1Feed
NumberCutting
Speed
NumberNumber Cutting
Feed
Feed
Step
Speed
Speed
ofCutting
Flute
Tool
Size
Size
-1 -1
Tool Tool
Size) ) -1 ) (mm/min)(mm/min)
(mm)
(mm)
(min
(min
of
Flute
Flute
(mm/min)(min
ofof Flute

Tool
Tool
PCD-MXD
PCD-MXD

PCD-MXD

Drilling
Drilling
PCD-MXD

Drilling
Drilling

φ 0.6
φ 0.6
Conventional
Conventional
Diamond
DiamondCoatedCoatedDrillDrill φ 0.6

Conventional
Conventional
DiamondCoatedDiamondCoatedDrill Drill

StillStill
Running
Running120120Still Running

31 31
NumberNumberof Holesof HolesConventional
Diamond Coated Drill

8,000 1.0

Approx.
Approx.
4 times
4 timesthethedurability
durability

0 0

PCD-MXD

1.01.0

2 8,000

PCD-MXD
PCD-MXD
Conventional
Conventional
Diamond
DiamondCoatedCoatedDrillDrill

PCD-MXD

8,000
8,000

2 2

φ 0.6 2

Still Running

Approx. 4 times the durability

Conventional
Diamond Coated Drill
0

Approx. 4 times the durability
31

0

120
Number of Holes

31

120

Number of Holes

Figure 1. Silicon carbide processing example: drilling 120 holes with a single tool

13 SHAPE IT   Technical Insight

0.01
0.01

Feed
(mm/min)
Step
Depth
Depth
(mm)
(mm)
(mm)

3.83.8
Blind
Blind
Hole
Hole

1.00.01

Step

(mm)
Depth
(mm)

Coolant
Coolant

Water-soluble
Water-soluble
Coolant
Coolant

3.8
0.01
Blind Hole

Depth
(mm)

Coolant

3.8

Water-soluble
Coolant
Blind HoleCoolanWater-soluble C

PCD Radius End Mill “PCD-MRM”
The PCD-MRM is composed of solid PCD engineered for long tool life in the milling of hard and brittle materials. Its
ultra multi-flute configuration makes roughing highly efficient while enabling a mirror finish. By featuring a helix
flute geometry, cutting resistance is minimized. The PCD-MRM is suitable for hard and brittle materials such as
cemented carbide, ceramics and quartz glass.

Machining Examples

WORKPIECE
As
illustrated in figure 2, the PCD-MRM demonstrates high machining efficiency by removing a volume
WORKPIECE
of 380 mm3 in cemented carbide in just four and a half minutes with normal wear progression and cancontinued
to be used.
Work MaterialWork Material

Cemented Carbide
Carbide (V30)(V30) 88.5
88.5 HRA
HRA
Cemented
WORKPIECE
WORKPIECE

Size
ofMaterial
Workpiece
Work
Work
Material
SizeofWorkpiece

88.5HRAHRA
Cemented
Carbide(V30) 88.5
20 Cemented
mm
20Carbidemm (V30)
20
mm
xx 20
mm
SizeofofWorkpiece
Workpiece
Size

RemovedVolumemmx x20
20mm
mm
2020
mm
RemovedVolume33
380mm
380 mm3
Removed Volume

Cutting edge condition after machining
Cutting edge condition after machining

Removed Volume

380 mmNo.

No.
No.No.

1

1 1
1 2
2

2
2

3

Cutting edge condition after machining

Cutting edge condition after machining

Process

Tool

Process
Process

Tool

Process

Number Cutting Speed
Feed
Depth of Cut
NumberDepth of Cut
Cutting
Speed CoolantFeedMachining Time
Tool Size(mm/min)Cutting(mm)(min ) Numberof Tool
Flute Size
Tool
Feed
Depth
of Cut-1Depth of Cut
Number Cutting
Feed (minSpeed)(mm/min)(mm)
ofSpeed
Flute
Tool
-1
Coolant
MachiningTime
Tool Size Tool Size (min-1)
(mm/min)
(mm)
(min
)
(mm/min)(mm)of Flute
of Flute
ap = 1.6
1:10-1

Trochoidal Slotting

φ2 x R0.1 x 3

PCD-MRM

Trochoidal
Slotting
Trochoidal
Slotting

Side MillingSlotting
Trochoidal

PCD-MRM

Side MillingSide MillingSide Milling

φ2 x R0.1 x 3

PCD-MRM
PCD-MRM

ae = 0.1

25,00015

15

φ2 x R0.1 x 3
φ2 x R0.1 x 3

1,000

25,000

15
15

1,000

ap = 1.6
ae = 0.1

25,00025,000ap = 1.6 Air-blow
ae = 0.1
Air-blow

ap = 1.6
ae = 0.1

ap= 1.6
1:10= 1.6
ap
ae =
0.1
ae = 0.1

3:25

1,000
1,000

Machining Time
Machining Time
1:10
1:10

Air-blow
Air-blow

3:25

ap = 1.6
ap
= 0.1
1.6
ae =
ae = 0.1
Total Machining Time: 4:35

Total Machining Time: 4:35

Coolant
Coolant

3:25
3:25

Total Machining Time: 4:35
Total Machining Time: 4:35
Figure2. Shape processing of cemented carbide: removes a volume of 380 mm3 in just four and a half minutes
WORKPIECE

WORKPIECE

Work Material
Material
Work

Figure 3 depicts the PCD-MRM’s capability to complete roughing to
Cemented Carbide
Carbide (GU20)(GU20) 91.5
91.5 HRA
Cemented
mirrorfinishing in cemented
carbideHRA
with a single tool.

WORKPIECE
Work Material

Size ofof Workpiece
Workpiece
Size

Cemented Carbide (GU20) 91.5 HRA

30 mm
mm xx 3030 mm
mm xx t20
t20 mmmm
30

Size of Workpiece
30 mm x 30 mm x t20 mm

No.
No.

Process
Process

1
1

Roughing
Roughing

Tool
Tool

Tool Size
Tool Size

NumberNumberof Flute
of Flute

Processing
Processing
MethodMethodCutting Speed
Cutting-1(minSpeed)(min -1)

Feed
No.FeedProcess(mm/min)(mm/min)1

2
2

Finishing
Finishing

PCD-MRM
PCD-MRM

φ3 x R0.1 x 5
φ3 x R0.1 x 5

25
25

Down
Down
Milling
Milling

14,00014,00014,00014,0002

Roughing

Depth of Cut
(mm)
(mm)

Tool
Tool
Size
Depth of
Cut

Processing
NumberCutting Speed
Feed
Coolant
Machining(min -1) Time
Method Machiningof Flute
Coolant
Time(mm/min)
14,000350
350

φ3 x R0.1 x 5
PCD-MRM
ap = 0.005

ap = 0.005
ae = 0.45
ae = 0.45

25Air-blow

350
350

ap = 0.005
ap
ae==0.005
0.07
ae = 0.07

Water-soluble
Water-soluble
Coolant
Coolant

Finishing

Down

Air-blow Milling

6:54
6:54

14,000

44:14
44:14

Total Machining Time: 51:08
Total Machining Time: 51:08
Figure 3. Mirror finishing of cemented carbide: completes roughing to mirror finishing with just one tool

SHAPE IT   Technical Insight 14

Depth o(mm

350

ap = 0.
ae = 0350

ap = 0.
ae = 0PCD Chamfering Tool “PCD-MCM”
The PCD-MCM is composed of solid PCD engineered for long tool life and high machined surface quality evenin hard and brittle materials that are prone to chipping. By featuring a multi-flute configuration, machining
efficiency is enhanced. The PCD-MCM is suitable for hard and brittle materials such as cemented carbide,
ceramics and quartz glass.

Machining Example
As depicted in figure 4, the PCD-MCM is able to achieve both machining efficiency and good machined
surface quality even in quartz glass.

Tool Appearance
Tool Appearance
Tool Appearance

No.No.
No.

Process
Process
Process

Tool
Tool
Tool

1 1

Drilling
Drilling

PCD-MXD
PCD-MXD

2 2

Chamfering
Chamfering

1

2

Drilling

Chamfering

PCD-MXD

NumberFeed Depth
NumberCuttingCutting
Speed Speed
Feed
Tool Size
NumberCutting
Speed
Feed
ToolToolSize(mm/min)of Flute (min -1) (min -1-1)(mm/min)(mm)
Sizeof Flute(min )(mm/min)of Flute

φ 1.0 φ 1.0

φ 1.0

PCD-MCM
PCD-MCM 1 x 45° x1 2x 45° x 2

PCD-MCM1 x 45° x 2222

15,00015,0006

6

6
6

32,00032,00064

15,00032,000Depth
Depth
Coolant(mm)(mm)

Coolant

2.0
2.0
2.0
6 Blind Hole Blind Hole
Water-soluble
Water-soluble
Blind
Hole
Water-soluble
Coolant
Coolant
Chamfer Diameter
Chamfer Diameter
Coolant64
φ 1.8 Chamfer
Diameter
φ 1.8
64
φ 1.8
6

Figure 4. Chamfering of quartz glass: achieves good machined surface quality even in quartz glass

PCD Thread Mill “PCD-MTM”
The PCD-MTM is composed of solid PCD engineered for long tool life in the threading of hard and brittle materials.
By featuring a multi-flute configuration, machining efficiency is enhanced. Furthermore, its single thread form
reduces cutting resistance and minimizes the pitch diameter difference between the hole entry and inner hole.
The PCD-MTM is suitable for hard and brittle materials such as cemented carbide, ceramics and quartz glass.

Machining Examples
As depicted in figure 5, the PCD-MTM demonstrates five times the processing efficiency versus a
conventional tool in internal thread milling of Zirconia. In addition to the reduction of cycle time, good
thread quality is also achieved.

15 SHAPE IT   Technical Insight

Coolant

Tool

φ1.55 φxφ0.4-INT
1.55 x 0.4-INT
PCD-MTM
PCD-MTM

Tool
Tool

Zirconia
Zirconia

Material Material
Material
Conventional
Conventional
Conventional
Method Method
MethodElectroplated
Tool Tool
Electroplated

ThreadThread SizeThread Size
Size

M2 x 0.4
M2 x 0.4

PCD-MTMPCD-MTM
PCD-MTM4-min

4-min
4-min

Conventional
Conventional
Conventional
Electroplated
Tool
Electroplated
Tool
ElectroplatedTool

0

20-min 20-min
20-min

500

1055

10
15
10

15
20
15

20
25
20

25
25

MachiningMachining
Time (min)TimeMachining
Time (min)(min)

ThreadingThreading
Length Length
mm (Through)(Through)Threading
Length 2.5 mm2.5

0.1 mm0.1 mm

Depth ofDepth
Cut ofDepth
of CutCut

Cutting
Cutting Speed
195 m/min(40,000(40,000
min-1) min-1-1)
Cutting Speed
Speed 195 m/min

Feed

10 mm/min
10 mm/minFeed

ThreadflanksurfaceinThread flanksurfacein goodcondition
Threadflanksurfacein good
good condition
condition

Cooperation: Sodick Co., Ltd.

Figure 5. Internal thread milling in Zirconia: 5 times the machining efficiency

Figure 6 is an internal thread milling example in quartz
glass. The PCD-MTM demonstrates high machining
efficiency and good thread quality.

Cooperation: Sodick Co., Ltd.

No.

No.
1

Process
Drilling

Tool
PCD-MXD

Tool Size
φ 1.6

Process

Tool

Feed
Cutting Speed-1)(mm/min)(minDrilling
1
PCD-MXD
2

3

Chamfering
10,000Threading

PCD-MCM
15
PCD-MTM2

Chamfering

PCD-MCM1 x 45° x 2

25,000190

3

Threading

PCD-MTM

φ1.55 x 0.4-INT(M2 x 0.4)

20,00041

Tool Size

Feed
Cutting Speed(mm/min)(min -1)Depth of Cut(mm) 10,000
φ 1.6

6.5 25,000
1 x 45° x 2(0.2 mm Step)
φ1.55 x 0.4-INT(M2 x 0.4)

20,000C0.2

Depth of Cut
(mm)

15

MachiningTime(0.2 mm Step)

190

C0.2

41

4
(2-pass)

Non-water-soluble
Coolant

4(2-pass)

Coolant

Machining
6.5
Time

Coolant

Non-water-soluble
0:50 Coolant

0:50

0:01

3:37

0:01

3:37

Figure 6. Internal thread milling in quartz glass: achieves high-quality threads even with high-efficiency machining

As a new standard for the processing of hard andbrittle materials, 6C x OSG proposes innovative
machining technology that does not compromise on
processing quality and production efficiency.
6C x OSG products are currently available in Japan,
China and Taiwan.

12

1. 6C x OSG is a cutting tool series optimized for the processing of hard and brittle materials with highprecision and good surface finish at a new level of geometric complexity.
2. PCD tools by 6C x OSG enable direct machining that is highly efficient and accurate, which shortens
machining time, reduces costs, minimizes energy consumption, and contributes to the realization ofcarbon neutrality.

SHAPE IT   Technical Insight 16

OSG’s 1/2-13 UNC modified bottom A-SFT spiral tap demonstrates superior performance in AISI316 cast stainless steel (JIS SCS14A).

Versatile and Efficient
A-Tap simplifies tool management and accelerates productivity in pump component production
Tim Eldridge
OSG USAFounded in 1933, Gorman-Rupp Company is a world leading
manufacturer of pumps and pumping systems.
Gorman-Rupp produces pumps for a wide variety of markets,
such as municipal, sewage, industrial, mining, construction,
petroleum, agriculture and more. The company’s extensive lineof pump products includes self-priming centrifugal pumps,
standard centrifugal pumps, submersible pumps, trash pumps,
priming assisted pumps, rotary gear pumps and air-driven
diaphragm pumps.
Employing 100 staff, Gorman-Rupp’s headquarters is located in
Mansfield, Ohio, United States, with over one million square feetof modern manufacturing and warehousing facilities. GormanRupp’s pumps are generally made of cast iron, bronze, AISI316
cast stainless steel (JIS SCS14A) and ASTM CD4MCu (duplex
stainless steel) to handle corrosive and abrasive fluids. With afleet of state-of-the-art, fully automated machining centers,
high-speed, high-quality machining of pump castings are madepossible.

Founded in 1933, Gorman-Rupp Company is a world leading
manufacturer of pumps and pumping systems. Employing 100 staff,
Gorman-Rupp’s headquarters is located in Mansfield, Ohio, UnitedStates, with over one million square feet of modern manufacturing
and warehousing facilities. Photo courtesy of Gorman-Rupp.

17 SHAPE IT   Customer Report

Since nearly every part produced includes drilled and tappedholes, it is no surprise that over the years, Gorman-Rupp has
utilized nearly every type and brand of tap available. While
Gorman-Rupp produces a wide variety of pumps, a great dealof commonality exists on the component level, allowing the
production of “part families” with minor differences such as partsize, hole location, material, etc. The number of holes required
to be processed vary per part due to the high-mix, low-volume
nature of the production. This has resulted in having many
duplicate tap configurations as well as a large mix of taps in
Gorman-Rupp’s tool crib. The company’s collection of taps ranges
from general-purpose to high-performance that are made byvarious cutting tool manufacturers.
The large variety of taps presented a challenge toGorman-Rupp, as it does in many other machine shops. Machine
operators often would choose the first tap they find from the tool
crib that matches the thread designation, which may not always
be ideal for the material or the application, resulting in mediocre
results.
To address this problem, Gorman-Rupp contacted OSG in hopesof consolidating its tap selection to a more versatile product thatworks in all the materials that the company uses in its productionof pump housing and various pump components. CNC
Programmer Tym Greenwood led the project on the GormanRupp side and laid out the goals of not only consolidating toolingto one manufacturer, but also increasing tapping efficiency andreducing overall cost per unit (CPU). It was important to GormanRupp to streamline its tap selection in a way without sacrificing
part quality or CPU.

1

2

3

1. Superb thread finish by the A-Tap. Gorman-Rupp is very pleased with the thread quality left by the A-Tap compared to their previous toolingchoice. Even in grey cast iron, the thread finish is exceptional.
2. Gorman-Rupp’s extensive line of pump products includes self-priming centrifugal pumps, standard centrifugal pumps, submersible pumps,
trash pumps, priming assisted pumps, rotary gear pumps and air-driven diaphragm pumps. Photo courtesy of Gorman-Rupp.
3. The A-Tap is known for its superior chip evacuation capability. It is an all-purpose tap series developed to accommodate a wide variety ofmaterials and machining environments, helping manufacturers simplify tool management.

After reviewing the list of taps Gorman-Rupp had used in the past
12 months, becoming familiar with the parts and manufacturing
processes noting the common materials, OSG saw an opportunity
to utilize the A Brand 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 andapplications. Achieving trouble-free chip evacuation with a spiraltap in blind holes is particularly challenging and is a main causeof headaches for many manufacturers. To resolve this problem
and to improve the ejection of chips, OSG’s A-Tap A-SFT has
adopted a variable helix flute design, which encourages stablechip evacuation. The helix angle changes from the chamfer,where chips are formed, to the flutes, where chips are evacuated.
This unique geometry enables greater chip control that can help
produce tightly compacted chips for easy ejection from the hole.
To accommodate a wide range of cutting conditions, powdered
metal HSS and OSG’s V coating have been employed in this series
to achieve excellent wear resistance. In addition, to enablehigh-speed machining, the A-Tap series incorporates a uniquecutting edge design that emphasizes sharpness. Not only does
the A-Tap series perform well in general steel, it also excels indifficult-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. Available in spiral flute and spiral point, theA-Tap can efficiently tap nearly any material, making it the mostversatile, high-performance tap on the market.
The unique features of the A-Tap make it a perfect choice for
Gorman-Rupp to utilize in its tap consolidation project. Once
the A-Tap was identified as a potential solution, the highest
usage taps were brought in for testing on a variety of machines,
materials and applications.
For a AISI316 cast stainless steel (JIS SCS14A) application, testing
took place on a Mazak 630 horizontal machining center using
OSG’s 3/8-16 UNC modified bottoming A-SFT spiral flute tap(EDP# 1650511608). The drill hole size was 0.323-inch (blind hole)and the tapping length was 1-inch. Soluble coolant was applied
for the machining. The cast stainless steel housing part has an
estimate annual production of 25,000 pieces. Both the competitor
spiral flute tap and OSG’s A-SFT were used at a spindle speed of

200 rpm, cutting speed of 19.63 sfm, feed rate of 0.0625 ipr and12.5 ipm. The cycle time was 9.6-second. The competitor tool life
was 250 pieces whereas OSG’s A-SFT was able to complete
300 pieces. The tool price of the A-SFT is also about $8.50 USD lessthan the competitor tool. Taken in consideration of the tool cost,machine cost, tool change time and other factors, the total CPU is
reduced by 8 percent versus the competitor tool.
For a ductile cast iron application, testing took place on a
Mazak 630 horizontal machining center using OSG’s 1/2-13 UNC
modified bottoming A-SFT spiral flute tap (EDP# 1650512708).
The drill hole size was 0.437-inch (blind hole) and the tapping
length was 1.25-inch. Soluble coolant was applied for themachining. The cast iron housing part has an estimate annual
production of 25,000 pieces. The competitor spiral flute tap wasused at a spindle speed of 350 rpm, cutting speed of
45.81 sfm, feed rate of 0.077 ipr and 26.95 ipm. The cycle time
was 5.6-second and the tool life was 400 pieces.
OSG’s A-SFT was used at a spindle speed of 530 rpm, cutting
speed of 69.38 sfm, feed rate of 0.077 ipr and 40.81 ipm. The cycle
time was 3.7-second and the tool life was 600 pieces. The tool
price of the A-SFT is also about $12 USD less than the competitor
tool. By switching to the A-SFT, Gorman-Rupp is able to improve
1.5 times the tool life and reduce cycle time by 34 percent. Taken
in consideration of the tool cost, machine cost, tool change timeand other factors, the total CPU is reduced by 38 percent versus
the competitor tool.
The above CPU reductions combined with the convenience of
having only one tap style that works for all materials showed
Gorman-Rupp the value of the A-Tap series.
“The positive results we are getting combined with the local
support make the decision to choose OSG as our primary tap
provider an easy one,” said Tym Greenwood, Gorman-Rupp CNC
Programmer and Project Manager.
Based on a number of tests conducted, Gorman-Rupp concluded
that a 20 percent cost reduction versus the prior year can beachieved on all tapping operations. Since then, Gorman-Rupp has
converted all of its standard taps to the A-Tap and will continue tofurther drive efficiency and cost reduction across all areas of themachine shop.

SHAPE IT   Customer Report 18

From left, OSG Italia Engineering Manager Andrea Severi, Olimac Production Manager Alessandro Martini and OSG Italia Piedmont
Area Salesman Riccardo Costamagna pose for a photograph at Olimac’s manufacturing facility in Margarita, Cuneo, Italy.

Perfect Chip Control Even
in Deep HolesVPO-DC-MT cutting tap reduces tapping cycle time and increases tool life in steel
bracket code production for corn heads
Andrea Severi
OSG Italia
In tapping applications, most machining troubles areusually caused by unstable chip evacuation. The savingof time in machining and downtime caused by the lackof chip control can significantly reduce manufacturing
cost even in small lot production. The elimination of
cutting chip problems in its robotic production systems
is one of the key objectives of Olimac s.r.l., a world leader
in the design and manufacturing of corn heads used for
harvesting.
Founded in 1950, Olimac is a leading solution provider
for the agriculture industry with innovative corn heads
engineered for higher efficiency in corn cultivation.
Today, Olimac exports more than 98 percent of its
production all over the globe. Employing approximately
200 staff, Olimac is headquartered in Margarita, aprovince of Cuneo in the Piedmont region of Italy, with aproduction area of over 45,000-square-meter.

19 SHAPE IT   Customer Report

Olimac’s manufacturing plant is equipped withnumerous CNC machining centers, with capabilities tooptimize work cycles for various lot sizes in different
materials, such as alloy steels, cast iron and carbon steel.
Olimac’s production facility is completely automatedwith integrated robotic production systems to control allcomponents with superior quality. Advanced CAD-CAM
tools are used in Olimac’s research and design division,
where production processes are transmitted to themachine tools with every working phase being traceable
and monitored. In the corn head manufacturing sector,
Olimac prides itself as the only company with capabilities
to completely design and build all components of thecorn head inside its own plant. As a forward-thinking
company that is attentive to new technologies, Olimac
continuously seeks process optimization to facilitate
further growth.

1

4

2

5

3

6

1. Olimac’s plant is located in Margarita, a province of Cuneo in the Piedmont region of Italy.
2. Olimac’s manufacturing plant is equipped with numerous CNC machining centers, with capabilities to optimize work cycles for various lot
sizes in different materials, such as alloy steels, cast iron and carbon steel.
3 & 4. Fixed bracket codes made of C40 steel (JIS S40C) for corn heads. Olimac has been manufacturing bracket codes since 2015 in various
shapes and quantity.
5. Inside Olimac’s manufacturing plant in Margarita, Cuneo, Italy. Olimac’s production facility is completely automated with integrated
robotic production systems to control all components with superior quality.
6. OSG’s VPO-DC-MT form E cutting tap with center-through coolant mounted on a synchronized tap holder.

Recently, Olimac was looking to improve tool
performance on its fixed bracket code production madeof C40 steel (JIS S40C) for corn heads. The company has
been manufacturing bracket codes since 2015 in various
shapes and quantity. For this part, the current annual
production volume is estimated to be around
25,000 pieces. Each bracket code requires the threadingof two M14 x 2 holes at a depth of 36 mm. The pre-hole isdrilled with a 12 mm diameter carbide drill at a depth of
39 mm. The parts are machined using a Mazak
HCN-5000 horizontal machining center.
Originally, Olimac was using a competitor tap for theapplication and experienced chip control problems
and poor tool life. In search of improvement, Olimac
Production Manager Alessandro Martini contacted OSG
to optimize cycle time, increase tool life and enhancechip control that has been causing enormous downtime
problems in Olimac’s robotic production systems.
Shortly after, OSG Italia Engineering Manager Andrea
Severi and OSG Italia Piedmont Area Salesman Riccardo
Costamagna visited Olimac’s production facility toevaluate the application. After analyzing the cutting
condition, the dual recommended using theM14 x 2 VPO-DC-MT form E cutting tap withcenter-through coolant (EDP# 48038191) mounted on asynchronized tap holder with ER16 collet.

The VPO-DC-MT is a powder metal straight fluted tap
engineered to excel in cast iron and cast aluminum
applications. The high rigidity geometry of this tool
combined with OSG’s V coating and the highly wear
resistant powder metal substrate guarantee
high-performance process stability.
For the machining, the competitor tap was used at a
cutting speed of 15 m/min (340 rpm) and averaged
4,800 holes. The VPO-DC-MT tap, on the other hand, wastested at a cutting speed of 18 m/min (410 rpm) andaveraged 8,200 holes. Comparing the cutting parameterand result against the competitor, the VPO-DC-MT
demonstrated a time saving in the tapping process of
20 percent and also boosted tool life by 70 percent.
Thanks to its unique cutting geometry, the VPO-DC-MT
tap enables the generation of short and compact cutting
chips even in alloy steels, pre-hardened steels, andmedium-carbon steels such as C40. The VPO-DC-MT offers
an excellent solution to controlling cutting chips when it
is not possible to utilize a forming tap.
For Olimac, the VPO-DC-MT tap has successfully
eliminated cutting chip problems correlated to machine
downtime, enabling greater production efficiency while
also decreasing processing costs, which led to a verysignificant economic saving for the company.

SHAPE IT   Customer Report 20

From left, Polund founder Ole Tolderlund, OSG Scandinavia sales representative Morten Larsen and Polund founder Lars Pors pose for a
photograph at VTM Summit in April 2023. Held in Odense, VTM Summit is an important trade fair for machine tools, tools and equipment forthe metalworking industry in Denmark. Polund’s PRO-CLAMP vise was used at the OSG booth for demonstrations during the exhibition.

Clamping Productivity
AE-VML long carbide end mill accelerates performance in clamping system productionPeter Cramer Jensen
OSG Scandinavia

Founded in 1998, Maskinfabrikken Polund A/S (Polund) is a manufacturerof clamping systems for CNC machines and a subcontractor for
metalworking. Employing 10 staff, Polund is located in the town ofOtterup in central Denmark, with an estimate production floor space of
1,600-square-meter.

12

1. Located in the town of Otterup in central Denmark,Maskinfabrikken Polund A/S (Polund) is a manufacturerof clamping systems for CNC machines and a
subcontractor for metalworking.
2. The PRO-CLAMP Systems was invented more than 14
years ago to optimize Polund’s own production.

21 SHAPE IT   Customer Report

Initially, Polund was primarily involved with subcontractor work
especially for milling and surface grinding. Today, however, Polund’s
own brand – PRO-CLAMP Systems – has become the core product of thecompany. The PRO-CLAMP Systems was invented more than
14 years ago to optimize Polund’s own production. At the time, Polund
felt that its advanced machinery could be better optimized if less time
was spent on adjustments and chip removal during production. Thus,
the PRO-CLAMP Systems – a fast and flexible clamping solution – wascreated where cleaning, adjusting and clamping of many items can bedone in minimal time. Today, the PRO-CLAMP Systems has advanced
considerably. In addition to the standard lineup, Polund also offers
customized solutions to help customers maximize production capacity.
Currently, 10 CNC machines at Polund are used to produce
PRO-CLAMP standard vices and customer specific clamping systems.
About 70 percent of the production is standard and 30 percent iscustom. Moreover, approximately 50 percent of the production isexported overseas to countries such as Germany and the United States.

Recently, Polund was looking to enhance productivity on
the production of a custom clamping system that requires
the milling of deep pockets and a high amount of metal
removal. Six parts made of Uddeholm Holdax(DIN 1.2311; prehardened steel) are needed to be milled. The
parts are machined using a Mazak VTC 830 SR machining
center (BT40 spindle). MST’s shrink fit tool holder is
employed for the processing.
3

As an existing customer, OSG was called in to offer asolution. OSG Scandinavia sales representative Morten
Larsen visited Polund’s facility to inspect the cutting
condition. Upon a detail evaluation of the application,
Larsen recommended the AE-VML anti-vibration long
carbide end mill (EDP# 8556378, 16 x 64, 5-flute).
The AE-VML long carbide end mill is a part of
OSG’s AE-VM anti-vibration carbide end mill series
designed to attain an all-new level of 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 and potential damage to the workpiece evenunder aggressive cutting conditions. Cutting vibration isminimized with the AE-VM’s unequal spacing of teeth andvariable-lead geometry. Furthermore, its unique flute form
helps facilitate trouble-free chip evacuation to enable stable
and consistent performance. With the addition of OSG’soriginal DUARISE coating, tool life can be enhanced by its
excellent lubricity, superior friction-resistance and highoxidation temperature qualities. Available in a wide variety
of styles and specifications, the AE-VM series is designed toaccommodate a wide range of milling operations in stainlesssteel, cast iron, carbon steel, alloy steel and hardened steel.
Polund was originally using a 16 mm diameter 5-flutecompetitor solid carbide end mill with TiCN coating for theapplication. The competitor end mill was used at a cutting
speed of 251.2 m/min (5,000 min-1), a feed of 3,500 mm/min(0.14 mm/t), feed per revolution of 0.7 mm/rev, an axial
depth of cut of 40 mm, and a radial depth of cut of 0.5 mm.

A PRO-CLAMP 5-Axis vice made by Polund, which has along clamping distance and is ideal for all kinds of clamping
associated with 5-Axis machining.

45

3. One of the six parts of a custom clamping system.
4. OSG’s AE-VML end mill in a MST shrink fit chuck.
5. Photograph of the AE-VML end mill after 500 minutes of millingin Uddeholm Holdax (DIN 1.2311). The AE-VML exhibited normal
wear and could continue to be used.

Water-soluble coolant (8 to 18%) was applied. The competitor
end mill achieved a metal removal rate of 70 cm3/min.
OSG’s AE-VML carbide end mill was tested at a cutting speedof 140.7 m/min (2,800 min-1), a feed of 7,000 mm/min(0.5 mm/t), feed per revolution of 2.5 mm/rev, an axial depthof cut of 40 mm, and a radial depth of cut of 1 mm. Air-blow
was used for the coolant. The AE-VML achieved four times themetal removal rate of 280 cm3/min versus the competitor tool.
The competitor end mill reached its tool life after milling
250 minutes. The AE-VML, on the other hand, was able tocomplete 500 minutes of milling, exhibited normal wear, andcould continue to be used. Test results have demonstrated
that an estimate of 10 hours could be saved by switching
to the AE-VML for milling the six custom parts. The AE-VML
has outperformed the competitor tool in both machining
efficiency and tool life. With the satisfactory result, Polund
will look to apply the AE-VML in other applications to further
optimize productivity and maximize performance.

The AE-VML long type end mill is a part of the AE-VM
anti-vibration carbide end mill series designed to attain an all
new level of milling efficiency coupled with superb finish quality
suitable for a variety of milling applications.

SHAPE IT   Customer Report 22

Fundimig has been manufacturing CNH swivel housings since 2017 with an annual estimate production volume of 4,200 pieces. The parts
are machined using a Heller H 4000 4-axis horizontal machining center.

Tool Consolidation
Custom carbide step drill consolidates machining process and increases tool life inswivel housing production
Yasmin Natacha Nunes da Silva
OSG Sulamericana

Founded in 1982, Fundimig Indústria De Peças e Componentes LTDA. (Fundimig) is a company that specializes in
the casting and machining of parts and components for the agricultural, automotive and industrial parts markets.
Employing 1,120 staff, Fundimig is headquartered in the center-west of Minas Gerais in southeastern Brazil, with anestimated production area of 38,300-square-meter. As a specialist in the production and machining of gray and nodular
iron castings, Fundimig has been operating for more than 30 years in the national and international markets with aproduction capacity of over 3,000 tons of parts per month, distributed across three manufacturing units, all of which are
ISO 9001-2008 and IATF 16949 certified.

23 SHAPE IT   Customer ReportTo maximize performance, the engineering team at
OSG Sulamericana tailored a 12.5 mm diameter
2-flute carbide step drill based on its High-Tech toolseries. The custom drill features a unique cutting edge
geometry and is coated with OSG’s original EgiAs
coating for long tool life and excellent performance incast iron applications.
Under identical cutting condition as the competitor drill,
OSG’s custom step drill is able to complete
950 parts (13,300 holes) before wearing out, which
is nearly four times the durability. Moreover, with
OSG’s tooling proposal, Fundimig has eliminated thechamfering tool, which reduced tooling cost, setup time,and enhanced the entire production process.
With an aim for continuous improvement, Fundimig
always seeks to exceed market expectations in all
aspects. As a valuable partner, Fundimig has consistently
counted on OSG for processing improvement.

OSG’s custom 2-flute carbide step drill is being presetted on a
Zoller tool presetter.

Recently, Fundimig was looking to enhance its drilling
process on a CNH swivel housing production, minimize
costs and decrease machine setup time. Fundimig has
been making these parts since 2017 and has an annual
estimate production volume of 4,200 pieces. The swivel
housing is made of ductile cast iron GGG50. Each part
requires the processing of 14 M14 x 1.5 6H holes. The
pre-drilled holes are 12.5 mm in diameter with a depthof 26 mm (through holes). The parts are machined usinga Heller H 4000 4-axis horizontal machining center. A
shrink fit tool holder is used for the fixation. Soluble oil isused for the coolant during machining.

“We trust the quality of OSG’s products and in
the technical capacity of its group,” said Fundimig
Engineering Manager Paulo Andres. “This time it was
no different. We are very satisfied with the resultsby achieving our objectives in reducing costs andimproving product quality,” said Andres.

A custom 12.5 mm diameter 2-flute carbide step drill tailored by
OSG Sulamericana’s engineering team.

Fundimig was originally using a competitor
2-flute coolant-through carbide drill for the application.
After drilling, a 45-degree carbide chamfer is used. The
competitor carbide drill was used at a cutting speed of
90 m/min (2,300 rpm) and a feed rate of 690 mm/min(0.3 mm/rev). The competitor drill averaged 250 parts(3,500 holes) per tool.
During a visit to Fundimig’s facility, OSG Sulamericana
Sales Engineer José Eisenhower Galdino Vieira learnedof the company’s challenge. Upon a detail evaluation of
the application, Vieira recommended a custom tool.

From left, Fundimig Engineer Tiago Nazareno, OSG Sales Engineer
José Eisenhower Galdino Vieira, and Fundimig Engineering
Manager Paulo Andres pose for a photograph at Fundimig’s
manufacturing facility in Cláudio, Minas Gerais, Brazil.

SHAPE IT   Customer Report 24

A-XPF
Forming Tap

The A-XPF is OSG’s latest high-efficiency andmulti-purpose forming tap. The A-XPF forms
threads by plastic deformation of the work
material and does not generate cutting chips.
The A-XPF enables the reduction of toolchange time caused by cutting chip troubles
and machine downtime required for removing
accumulated cutting chips. The A-XPF featuresa special chamfer specification (pat. in Japan)
for achieving low thrust. Its special thread
configuration (pat. in Japan) improves cuttingedge rigidity, making it less prong to chipping.
The A-XPF is made of powder metallurgy HSS(CPM) with high wear resistance.

With the addition of a special coating (pat.
pending in Japan), tool life can be further
enhanced.
The A-XPF is a revolutionary product thatexcels in a wide range of work materials andcutting conditions with improved productivity,
such as small-diameter threading in stainlesssteel and high-speed threading in
high-hardness material of 30 HRC.

ADO-SUS
Carbide Drill for Stainless Steels and Titanium Alloys

Work hardening, welding, elongation of
cutting chips and poor thermal conductivity
are common problems in the machining ofstainless steels and titanium alloys. The
ADO-SUS features a tool geometry thatemphasizes sharpness to reduce work
hardening, thereby prolonging tool life forpost-processing including reaming andtapping. Its unique flute form encourages
the creation of small cutting chips, which isessential for trouble-free chip evacuation.
Furthermore, the ADO-SUS adopts a unique

25 SHAPE IT   Product Pickup

oil hole design “Mega Cooler” for diametersizes above 6 mm in 3D and 5D to suppress
heat generation and to facilitate smoothchip evacuation. With the addition of
OSG’s WXL coating, stronger adhesion strengthand resistance against welding can beachieved.

AE-CRE-H
High Efficiency Radius Type Carbide End Mill

The AE-CRE-H radius type carbide end millfeatures multi-flute and unequal spacing teeth
specifications to suppress chattering for stable
and high-efficiency roughing of high-hardness
steels. To achieve both cutting edge strengthand good chip evacuation, the AE-CRE-H isengineered with a 2-stage gash shape and alarge chip pocket. Furthermore, the AE-CRE-H
features a large positive R shape and shortflute length with high tool rigidity to allow
large depth of cut and high-feed milling, which
is ideal for high-speed direct engraving.

AE-HFE-H
High Feed Radius Type Carbide End Mill

The AE-HFE-H high feed radius type carbide
end mill reduces cutting resistance with its
unique composite radius shape, and enables
high-speed, high-feed machining even atoverhang length of L/D = 7 in high-hardness
steels. To achieve both cutting edge strengthand good chip evacuation, the AE-HFE-H
is engineered with a 2-stage gash shapeand a large chip pocket. Furthermore, with
its unequal spacing teeth configuration,
chattering can be suppressed to enable stable
and highly efficient machining.

SHAPE IT   Product Pickup 26

From left, San-en NeoPhoenix’s mascot Dunker and OSG’s mascot Tap-kun pose for a photograph before the start of March 3rd’s home gameat the Toyohashi City General Gymnasium in Aichi, Japan. Photo courtesy of San-en NeoPhoenix.

Fusion of Sports & Manufacturing
OSG showcases aluminum milled basketball workpieces at San-en NeoPhoenix home game
OSG Corporation collaborated with
San-en NeoPhoenix, a B. League professional
basketball team based in the central region of Japan,
during a home game at the Toyohashi City General
Gymnasium on March 3, 2024.
OSG strives to contribute to the sustainable
development of local communities by serving as a
top sponsor of San-en NeoPhoenix to support local
professional sports. In addition to hosting a minibasketball game at the event to promote sports,
OSG displayed two aluminum milled basketball
workpieces at the gymnasium to inspire interest in
the manufacturing industry.

27 SHAPE IT   OSG NewsOSG strives to contribute to the sustainable development of local
communities by serving as a top sponsor of the professional basketballteam San-en NeoPhoenix to support local professional sports.

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1 & 2. A mini basketball game was held at the OSG booth during the March 3rd home game where spectators would receive prizes for participating.
3 & 4. From left, a special collaborative edition tote bag and happi coat (traditional Japanese short jacket worn at a festival) featuring San-en
NeoPhoenix’s mascot Dunker and OSG’s mascot Tap-kun. They were given out as prizes at the March 3rd home game.

OSG has created a life-size basketball made ofaluminum as an attempt to connect sports andmanufacturing. Iida Craft’s scanning technology
creates 3D data that reproduces even the complex
grain shape of the basketball surface. The 3D data
was accurately carved out using CAM software from
Aikoku Alpha Corporation. The aluminum basketball
net was a collaborative project by machine builder
GROB, CAM/CAD solution developer OPEN MIND and
OSG in Germany. It is a workpiece that demonstrates
the possibilities of 5-axis milling.
OSG supports San-en NeoPhoenix’s management
philosophy in “making the San-en region a vibrate
and smiling town,” and will continue to work toward
promoting local sports and community growth tocontribute to a prosperous future.

Watch the milling
process of thealuminum basketball:

From left, a life-size basketball and basketball net made of aluminum
were displayed at the March 3rd home game of San-en NeoPhoenix in
Toyohashi, Aichi, Japan.

Watch the milling
process of the aluminumbasketball net (video
courtesy of OPEN MIND):

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OSG Around the World
Employee Interview with

Agnieszka Majer
Tell us about your background.
I am a business manager by education. I began myprofessional career at age 20 and gradually climbed thecorporate ladder while working and studying full time.
For the first few years of my career, I worked at a national
distributor as an assistant supporting sales in the cutting
tool industry. I was assigned to the threading divisionand the taps stole my heart ever since. I was responsible
for contacts and sales of various tap brands, including
OSG. Later in my career, I completed postgraduate
studies in pedagogy and earned an MBA degree toverify and expand my knowledge in the field of business
management. I also have a diploma in coaching andmentoring. I have been constantly improving myknowledge and qualifications not only in the field ofmetalworking, which helps me become a better leader
and person in general.

ProfileLocation: Poland
Position: General Manager at OSG Poland
Joined OSG: 2015
Motto: “There is no evil that does not turn out to be good.”

Tell us about your experience at OSG and your daily routine.
In 2015, I was offered with an opportunity to run an OSG company in Poland. After returning from a trip to the OSG
headquarters in Japan, I took on this extremely interesting yet challenging task of distributing the best tools to customers in
Poland.
As OSG Poland’s General Manager, I deal with an array of tasks, coordination, and development supervision. I monitor andverify company activities on an ongoing basis, both sales and tasks related to other departments such as customer service,accounting, and logistics. Every week I would meet with department managers and salesmen. Additionally, every month I
would have a chat with employees individually about current issues, as well as their needs, concerns and joys. I like being
informed about positive results of my colleagues’ work, but I also appreciate when they share difficulties and concerns withme too. This not only develops but also gives us enormous experience, builds trust, and brings us closer to each other and ourgoals. OSG Poland has a team of experienced and trusted employees without whom we would not be where we are today.
I am also always in contact with our distributors to improve sales. Joint training, projects and implementations bring us to thegoal: the satisfaction of our customers. I regularly meet with key clients and suppliers. In addition to commercial issues, I place
great emphasis on the automation of processes, the development of programs and technologies that reduces manual workand unnecessary activities. It allows our company to be more efficient and makes our work sensible and organized.

29 SHAPE IT   Meet OSG

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1. Majer poses for a photograph withher husband, 20-year-old son, and8-year-old goddaughter.

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2 & 3. When Majer is not working, sheenjoys taking trips to the lake, the sea,or to the mountains.
4. Majer and her German Shepherd Fibi.

What is most challenging about your work?
Working with people is exciting, desirable, but at the same time the most difficult task. Active listening is what I havebeen working on lately. It is quite a challenge for me because I am a talker by nature. However, this is often the key
to both sales and mental success - the enormous satisfaction of understanding and being understood. I think it iswhat everyone wants, including our customers. The rest is a matter of strategy, planning, as well as working smartly
and effectively.
What is unique about OSG Poland?
OSG Poland distributes extraordinary products that our competitors in
the region do not have. These tools make us special. Our cooperativeand involved team offers customers flexible yet personalized
approach to fulfill every request. Last but not least, I am the firstwoman in Europe to take on the position of General Manager at OSG,
which I am very proud of.
The office building of OSG Poland, which was established in 2016.

What is your favorite OSG tool?
I appreciate many OSG products, but my favorite tools are taps due to their reliability. No matter
how complicated the application is, OSG’s taps always finish the job with success and complete
customer satisfaction.
Developed in 2023, the A-XPF is a highly efficient multi-purpose forming tap series engineered to excel
in a wide range of work materials and cutting conditions with improved productivity, such as smalldiameter threading in stainless steel and high-speed threading in high-hardness material of 30 HRC.
OSG has been manufacturing taps since the company’s founding in 1938, more than 86 years ago.

How do you spend time on your day off?
When I am not working, I enjoy spending time with my beloved husband, my 20-year-old son, and my 8-year-old
goddaughter. Some of our favorite activities include reading books, watching movies with our cats, walking ourdogs, taking trips to the lake, the sea, or to the mountains. I also enjoy spending time with friends at the theater andcinema, as well as doing yoga and winter swimming with bonfires. Another hobby of mine is singing, which gives
me a huge amount of energy, optimism, and willingness to act.

SHAPE IT   Meet OSG 30