OSG Global Tooling Magazine

WINTER 2022

A Clean Solution
Thread forming withmulti-groove
Technical InsightAT-2 Carbide Thread
Mill with End-cutting
Edge

Customer Report

Pumped for Success
OSG Phoenix PD indexable drill
provides needed solution to
manufacturer of large cast pumps
Meet OSG

Employee Interview
in Belgium

Achieving carbon neutrality
in the “with COVID-19” eraA Message from the President
Almost two years have passed since the coronavirus(COVID-19) pandemic has taken center stage, making
the world revolve around this unprecedented crisis.
Rapid government responses and economic flexibility
have enabled Europe and the United States to recoverfaster from disruptions caused by the pandemic thanmany other regions. As a global company, OSG is also
confronted by many new challenges. Face-to-face service
has always been one of OSG’s greatest strengths, which
can no longer be easily provided during COVID-19. As
OSG continues to navigate the ever-changing saga of thecoronavirus crisis, flexibility has become a key to driving
the company forward. Our world today is filled withdata. It is crucial to detect, resist and counter the flood of
misinformation. By fact-checking and always challenging
the status quo, OSG will strive to continuously evolve tostay ahead of change.
The COVID-19 pandemic has impacted people’stransport behaviors dramatically. In addition, theimportance of carbon-neutral efforts has increased, and
OSG is in the midst of this great surge of change. By
establishing and committing to a deadline, Europe andthe United States took the lead in promoting electricvehicles (EVs) at once. The sense of speed toward EV isclear and has made the transition become more realand impending.
OSG has grown alongside the automotive industry for over 80 years, which continues to be the company’s largest
business domain. OSG strives to serve as the number one cutting tool manufacturer for our customers by providing highperformance cutting tools that meet new demand while responding to this industry’s ever-changing needs. Regardless ofthe supply chain reforms that accompany the EV shift, OSG will aim to maintain its top global market share and position as
the manufacturer of choice.
OSG has been manufacturing taps since its founding, and currently holds the world’s largest market share. OSG taps are
not only used heavily in the automotive industry, but are also favored by manufacturers from various sectors. BASS, oneof Germany’s top cutting tool brands introduced in this publication, has recently joined the OSG Group, helping us further
secure our position as the top tap market share holder.
As we continue to live in a VUCA world with volatility, uncertainty, complexity and ambiguity, OSG will further reinforce its
global organization with an emphasis on taps, which are the company’s greatest strengths and our origin, to make the year
2022 a starting point toward the realization of carbon neutrality.

Nobuaki Osawa
President & COO of OSG Corporation

1

SHAPE IT   ﻿CONTENTS Feature
SHAPE ITWINTER 2022

3 A Clean Solution

Technical Insight
9 AT-2 Carbide Thread Mill with End-cutting Edge

Customer Report
15 Pumped for Success
17 Triple Benefits
19 Superior Milling Solutions for High-hardness Steel

Product Pickup
21 AE-LNBD-N DLC Coated Carbide End Mill,AE-MSS-H and AE-MS-H Multi-flute Square Type and Radius Type Carbide End Mills

22 AM-HFC Carbide End Mill and PXHF-AM Exchangeable Head End Mill,
AT-2 Carbide Thread MillOSG News
23 OSG Corporation Hosts Die and Mold Web Exhibition
24 CIMT 2021

Meet OSG
25 Employee Interview in Belgium

SHAPE IT is a global cutting tool magazine published by OSG Corporation.
Publication Date: January 2022
Rights: Reproduction of the articles and photographs without permission is strictly prohibited.

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

SHAPE IT   ﻿

2

BASS’ manufacturing plant is located in the city of Niederstetten, Germany, with an estimated production floor of 6,500-square-meter.

A Clean Solution
Thread forming with multi-groove
Thomas Deschle, BASS GmbH & Co. KG
Magnus Hoyer, OSG GmbH
By nature, roll tapping forms screw threads throughplastic deformation of the work material. Because no
cutting chips are created, thread forming stands out asa clean machining method. As opposed to cutting taps,
thread forming tools can offer advantages such as longtool life and high process reliability even in large thread
depth applications. However, when using minimum
quantity lubrication (MQL) during thread forming,

3

SHAPE IT   Featurea negative effect may occur – the contamination ofpart and tool during machining. This condition isespecially apparent in MQL processing, whereas mostcontaminants are removed by the cooling lubricant in
wet processing. In addition to requiring subsequent
component cleaning, the contaminants may also
increase abrasive wear of the tool and reduce its service
life.

the ridges of the furrow. At the same time, it also
increases the cleansing effect of the cooling medium,
whether it is MQL or cooling lubricant, allowing theunwanted material particles to be removed from thegrooves and thus from the tool and part, enabling bothto come “clean” from the machining process.
An important factor during MQL-machining is toevacuate the air from the blind hole. In this case,traditional roll taps have a crucial disadvantage. The air
contained in the blind hole of the conventional straightgroove can only escape with a delay during thread
forming. While the tool is entering the hole and forming
the thread, the air within the bore hole is displacedand compressed to the bottom, with the coolinglubricant being pressed against a “wall” of air. Due tothis “counterpressure,” the coolant is unable to wet themachining area sufficiently to maximize its lubricating
effect. This is where the multi-groove comes in.

The cause for this contamination is small material
particles moving out of the ridges of the furrowof the tapped thread during processing. These
particles accumulate in the grooves of the roll
tap and will gradually contaminate both thetool and the part. To reduce this contamination,
BASS has taken extensive series of tests. Several
years of development work have resulted in theinternationally patented multi-groove as shown infigure 1. Due to the special geometry of this new
groove shape, contamination of the threading tool
used under MQL conditions can be eliminatedalmost completely.
Figure 1.

The special form of the multi-groove absorbs
dispersed material particles from

BASS’ internationally patented
multi-groove tool geometry for
longer tool life and clean parts.

SHAPE IT   Feature

4

Figure 2. The multi-groove’s functional principle:
With the traditional groove form as depicted on the upper half of figure 2, air within the bore hole (highlighted in blue) is
compressed to the bottom. Whereas the multiple groove configuration allows more air to escape and for the MQL-aerosol(highlighted in yellow) to sufficiently wet the bore hole wall. The result is an improved washing effect of the multiple
groove, where the outgoing air immediately removes material particles from the part during machining.

The larger volume of the multi-groove allows for theenclosed air to escape more quickly and for the bore
hole surface to be better wetted as depicted in figure 2.
The result: up to 30 percent longer tool life and adrastically enhanced process reliability.

The logical conclusion: the deeper the blind hole (> 2xD),
the greater amount of air has to escape - and thus thegreater the effect of the multi-groove.

BASS has developed an internationallypatented multi-groove geometry to control
contamination during roll tapping. The
multiple groove configuration increases
the cleansing effect of the cooling medium,allowing unwanted material particles to be
removed from the grooves and thus fromthe tool and part.

5

SHAPE IT   Feature

A core competency of BASS’
manufacturing in Niederstetten is
its salt bath heat treatment, where
toughness and hardness are optimized
for every batch in order to maximize
tool life at the highest quality.

Another factor influencing the effectiveness of the multi-groove is the pressure inwhich the aerosol is blown to the processing point. The usual ambient air pressureis 1 bar. Through compression within the blind hole, the aerosol thus pushes
against the “wall” of air with more than 1 bar. If the pressure of the aerosol is justslightly higher, a sufficient wetting of the bore hole wall by the aerosol cannot
be ensured. Thus, the tool life drastically decreases and contamination increases.
Particular for this reason, the multi-groove offers great potential especially underpoor processing conditions.

Watch how theMulti-Groove works

SHAPE IT   Feature

6

JUSTAR – a cutting tool grinding machine that BASS has developed together with machine builder Junker. BASS uses four JUSTAR cutting
tool grinding machines in its production. The JUSTAR is capable of handling a wide range of cutting tools in HSS and carbide with a single
machine. This is possible by its fully automatic grinding wheel changer. Each machine has a magazine for 30 grinding wheels, which areautomatically exchanged via a grinding wheel changer in the sequence of coordinated operations – thus enabling the most complex
geometries to be perfectly realized. The JUSTAR technology allows to grind finished tools from round bar stock in a single clamping setup.
Consequently, small batches – even of complex geometries – can be manufactured economically in a short period of time.

Combination with OSG’s ADO-TRS ‘Triple Revolution’ 3-flute coolant-through carbide drill
to achieve flawless holes for perfect threading
The ADO-TRS is one of OSG’s latest drilling innovations
for ultra-machining efficiency in a wide range ofmaterials. This 3-flute coolant-through carbide drill
series is highly recommended to be used in combination
with BASS’ multi-groove forming taps. The ADO-TRS’
3-flute specification offers greater balance than 2-flute
drills, which are more prone to chattering. Moreover,
the ADO-TRS enables superior roundness and improved
positioning in terms of hole precision. With capability

to excel under high-feed condition, the ADO-TRS is able
to minimize contact time with the workpiece material,
which reduces the probability of work hardening.
The ADO-TRS is available from diameter 3 mm up to
20 mm, in processing depth of 3xD and 5xD, and issuitable for applications in carbon steels, alloy steels,
mild steels, cast iron and hardened steels.

The ADO-TRS ‘Triple Revolution’ is one of OSG’slatest drilling innovations for ultra-machining
efficiency in a wide range of materials. Its unique
R gash geometry enables high thrust resistanceand exceptional chip control, which are common
challenges of 3-flute drills.

7

SHAPE IT   Feature

BASS GmbH & Co. KG’s headquarters in Niederstetten, Germany. Since its founding in 1947, BASS has focused on the development,
production and sales of powerful threading tools. In 2019, BASS was acquired by OSG Corporation to reinforce its strength in the European
market, global affiliated companies and OEMs.

About BASSBASS GmbH & Co. KG is a dynamic, medium-sized family
manufacturer based in Niederstetten, a German town
located near the medieval tourist site Rothenburg
ob der Tauber. Ever since the company’s founding by
the toolmaker Kurt Bass in 1947, BASS has focused on
the development, production and sales of powerfulthreading tools. In 2019, BASS was acquired by OSG
Corporation to reinforce its strength in the European
market and global affiliated companies.

BASS is renown worldwide for its high-quality
taps, especially for its roll taps and special tools.
A commitment to exceed customer expectationin products, services and delivery time is the corephilosophy of BASS’ 150 employees. Driven by
innovation, BASS serves clients from all fields – ranging
from automotive, mechanical engineering andmedical applications up to the machining of nuts, andmanufacturers of windmill turbines.

TECHNIK FÜR GEWINDESHAPE IT   Feature8

AT-2 Carbide Thread Mill
with End-cutting Edge
Drilling and threading combo tool for high-hardness steel applications
Tomonori Yoda
OSG Corporation Applications Engineer (Tap Development Division)

Thread milling cutters are considered tobe the optimum tooling choice for the
threading of difficult-to-machine materials
such as high-hardness steel. With threadmills, the tool load on the cutting edge canbe drastically reduced in the processing of
high-hardness steel versus cutting taps.
Furthermore, thread mills are able to divide
cutting chips into small and manageablepieces even in difficult-to-machine materials
with a tendency to form unstable chip shape.
Although thread mills are highly reliably
due to their low risk of breakage and longtool life characteristics, tooling choice willvary depending on the actual machining
environment and specific needs of the
manufacturer.

9

SHAPE IT   Technical Insight

AT-2

OSG’s latest AT-2 carbide thread mill is developed specificallyto combine the drilling of a drill hole and threading into asingle procedure even in difficult-to-machine materials suchas high-hardness steel.

Threading by Cutting Taps

Threading by Thread Mills

A thread is formed mainly by the chamfer sectionof a tap. In the machining of difficult-to-machinematerials such as high-hardness steel, heavy
tool load is concentrated on the cutting edge,
which can lead to tool damage. By increasing
the number of chamfers, the tool load on the
cutting edge can be dispersed. Specifically, it ispossible to disperse the tool load by lengthening
the chamfer and increasing the number offlutes in cutting taps. However, this method
has limitations. The more flutes, the smaller theindividual flute will become. With a limited flute
width, chip evacuation, cutting oil lubricity andcooling performance are reduced. Furthermore,
the chamfer length is particularly critical for theprocessing of blind holes, since the length islimited by the drill hole allowance. These effects
and correlations must be taken into considerationin the product development process.

Thread mill, in contrast, forms threads byintermittent cutting. Not only can the cutting
speed be adjusted, but also the feed amount,making it possible to reduce the tool load on
the cutting edge by cutting condition and offer
numerous qualities that can resolve common
tapping obstacles.
A thread mill’s cutting mechanism is similar to theside milling of an end mill. Even large-diameter
threads can be processed in machines with a small
horsepower compared to cutting taps. However,up until now, thread mills are not capable ofhandling work material with a hardness of around
60 HRC. With the release of the AT-2 carbide
thread mill – a drilling and threading combo
tool, more options are now available for effective
thread milling of difficult-to-machine materials
such as high-hardness steel.

In tapping, a tap can only advance one pitch per
revolution. Therefore, the feed per revolution isfixed by the processing pitch. Only the cutting
speed can be adjusted, and chip shape varies
depending on the difference in cutting speed.
Due to these limitations, threading by cutting taps
is considered to be a difficult process.

SHAPE IT   Technical Insight 10

Features & Benefits of the AT-2 Carbide Thread Mill with End-cutting Edge
The greatest feature of the AT-2 carbide thread mill is its ability to process high-hardness steel materials of
approximately 60 HRC without having to prepare a drill hole.

Figure 1. Left-hand cut configuration
Long tool life is achieved by climb milling. Utilization of left-hand cut
configuration to enable climb milling of right-hand threads.

Figure 2. Roughing Teeth
Distributes tool load.

Figure 3. High-strength cuttingedge shape (pat. in Japan)
Suppresses bending of the tool.

11 SHAPE IT   Technical InsightFigure 4. DUROREY coating
OSG original coating specially designed for high-hardness steel applications.

Coating Structure
Super Heat
Resistant Layer

Ultra-Fine Periodic
Nano-Layered
Structure

Adhesion Strength
Reinforcing Layer
Base Metal

The tip of the tool incorporates an end mill’s end-cutting edge configuration to allow it to perform helicaldrilling and threading simultaneously. By eliminating the need for a drill hole, sudden change in workpiece
configuration can be accommodated since it is possible for the AT-2 thread mill to process an internal
thread even after the workpiece has been quenched.
Figure 5. Helical drilling and threading simultaneously
No drill hole is required. The AT-2 thread mill enables stable machining without chip trouble.

Helical drilling+
ThreadingAchieves 2 processes

with 1 tool!

With the capability to achieve two processes with a single tool, machining efficiency is enhanced while theinitial production cost can also be significantly reduced.

SHAPE IT   Technical Insight 12

Figure 6. Long and stable tool life in high-hardness steel application
The AT-2 thread mill achieves higher thread quality compared to cutting taps.

Tool

Carbide hand tap for high-hardness steels

AT-2 φ6.2×16 P1.25

M8×1.25 3P

SKD11 (60HRC)

Work Material
Cutting Speed

45 m/min (2,310 min-1)

2 m/min (80 min-1)

Feed

83 mm/min (0.04 mm/t)

100 mm/min

None

φ6.8×23.5 mm (Blind)

Drill Hole Size
Internal Thread Size

M8×1.25

Threading Length

16 mm (2D)

Coolant

Air blow

Non-water soluble

MachineHorizontal Machining Center (BT40)

Vertical Machining Center (BT40)

Number of Holes

0

50

100

150

Correction

AT-2
Carbide handtap forhigh-hardness
steelsAs depicted in figure 6, the AT-2 thread mill exhibits
significantly longer tool life in comparison to a
carbide hand tap designed for high-hardness steel,thereby providing reduction in running costs.
The AT-2 thread mill incorporates a number of
unique tooling geometries. One of the mostprominent features is its left-hand cut configuration
as depicted in figure 1. Because the AT-2 threadmill is used without having to create a drill hole,
processing takes place one pitch at a time at hole

13 SHAPE IT   Technical Insight113 Holes

65 Holes200
Correction

79 Holes16 208

Holes

Holes

Chipping

entry. When processing a right-hand thread byclimb milling, a left-hand cut configuration isrequired. At the time of product development,
the right-hand cut configuration is also tested
with conventional milling. However, results haveshown that climb milling exhibited 20 percent
greater durability versus conventional milling. It
is important to note that the spindle will rotate
counterclockwise during use.

Figure 7. AT-1 one pass thread mill and AT-2 carbide thread mill
Suitable work materials and applications.

Hardened Steel

Steel, Stainless SteelNon-ferrous Metal

AT-1 One pass thread mill

AT-2 With end-cutting edge

■
■
■

■
■

Heat-resistant Alloy

Thread milling in 1-passCompatible thread classification:
M, U, Rc, Rp, NPT

Helical drilling + threading can be done simultaneously
Compatible with a wide range of work materials including high-hardness steels
Compatible thread classification: M, U, Rc, NPT

Compatible with a Wide Range of Materials
The AT-2 has been developed for the purpose ofprocessing high-hardness steel of 60 HRC, but it isalso suitable for other general steels. As illustrated
in figure 7, the AT-2 offers a wider processing range
than the AT-1 one pass thread mill. However, it isimportant to note that the AT-2 carbide threadmill is inferior to the AT-1 one pass thread mill andcutting taps in terms of tool life and machiningtime.

Although thread milling is a more mature cutting
process, it can offer greater reliability, surface
finish and precision that outperform conventional
tapping. With today’s demand for low quantity andhigh variation production, the highly versatile AT-2
carbide thread mill provides a new and effective
tooling solution that can accommodate a wide
range of work materials and applications.

Cutting taps are the fastest as they are able toprocess one pitch per revolution. The AT-1 is able
to achieve 1-pass threading, which the AT-2 isunable to accomplish. With the shorter processing
time, it can be assumed that the AT-1 offers longer
durability than the AT-2 thread mill.

Scan for details

SHAPE IT   Technical Insight 14

The OSG Phoenix PD indexable drill series is engineered for efficient and stable hole-making up to 5xD. The PD drill features a unique flute
design with high precision finish and integrated chip breaker. This series offers a broad insert lineup to accommodate a wide range of work
materials, such as steels, stainless steels, cast irons, aluminum alloys and non-ferrous metals.

Pumped for Success
OSG Phoenix PD indexable drill provides needed solution to manufacturer of large cast pumps
Scott Kemp
OSG USAThe mining and dredging industries are known for theharsh conditions that man and machine must endure.
These industries require the extraction and transportof large volumes of materials from one site to anotherusing large diameter slurry pumps. A slurry pump is acentrifugal pump that suspends solids in water, creating
a mixture referred to as slurry. Slurry pumps are widelyused to transport abrasive solids and are engineered
to withstand extremely abrasive materials such as
phosphate rock and tar sands. It is critical to have adependable and well-designed pump that expels large
quantities of corrosive materials in a safe manner.
GIW Industries, Inc. is a world leader in slurry andprocess pump solutions. Founded in 1891 in Augusta,
Georgia, United States, GIW has been manufacturing
slurry pumps for over 100 years. The company moved to

15 SHAPE IT   Customer Reporttheir current location in Grovetown, Georgia in 1964 andis currently undergoing a multi-million dollar expansion.
In 1996, GIW became a full subsidiary of KSB Inc., oneof the world’s leading manufacturers of pumps andindustrial valves. In 2014, the GIW® Minerals productbrand was established aiming to provide the best andlongest wearing slurry solutions in the industry.
GIW’s Grovetown plant currently employs approximately
650 staff members and produces around 200 parts
per week in batches of one to 10. GIW is continuously
looking for ways to improve quality and productivity
through their partnership with Fastenal, the company’s
onsite distributor. It was through this partnership that
GIW began to look to OSG for solutions to their large
diameter drilling issues.

GIW and Fastenal were experiencing problems withstock outages and discontinued competitor items
that interrupted the manufacturing of GIW’s slurry
pumps. Because GIW is an existing user of OSG HYPRO taps and has had positive experiences with OSG
tooling, they were willing to test the OSG Phoenix
P5D indexable drill on the pump bodies.
The OSG Phoenix PD indexable drill series isengineered for efficient and stable hole-making up to
5xD. The PD drill features a unique flute design withhigh precision finish and integrated chip breaker. This
series offers a broad insert lineup to accommodate awide range of work materials, such as steels, stainlesssteels, cast irons, aluminum alloys and non-ferrous
metals.
GIW’s pump bodies are made of cast steel or ductileiron. The parts are machined on very large verticaland horizontal boring mills, such as its newest
Giddings & Lewis floor type horizontal boring mill,using CAT50 tool holders. The number of holes andthe depth varies dependent on the application of
the pump. The competitor drill requires two different
grades of inserts, whereas the OSG Phoenix P5D
indexable drill (EDP# 7802794) utilizes the same
insert inboard and outboard, which has the potential
to reduce insert inventory by 50 percent. Moreover,the competitor tool was drilling +0.006” oversize.
Tool life was measured at 30 to 40 holes at a speed of
1,500 rpm and 0.005 ipr using CIMTECH 285 coolant.

By utilizing the
OSG Phoenix P5Dwith the insert grade
XP1010 optimal for castiron, the hole diameter isimproved to less than 0.006”
oversize, which is within GIW’s
tolerance. The hole finish also
improved, all while maintaining
identical speeds, feeds and tool life as
the previous tooling.

The OSG Phoenix P5D indexable drill is used to drill holes in GIW’s
production of slurry pumps made of cast steel and ductile iron.

By utilizing the OSG Phoenix P5D with the insert grade
XP1010 optimal for cast iron, the hole diameter was
improved to less than 0.006” oversize, which is within
GIW’s tolerance. The hole finish also improved, all while
maintaining identical speeds, feeds and tool life as theprevious tool. The insert grades, speeds and feeds canbe adjusted to further optimize the performance of
the Phoenix PD drill. Through the strong partnership
between GIW, Fastenal and OSG, insert inventory
and the number of vendors required can be reduced,
thereby greatly minimizing GIW’s overall costs. GIW
currently spends over $400,000 USD on tool bodies,
inserts and hardware. Savings in inventory reduction
alone is estimated around $1,200 USD per month. Witha strong partnership, innovative tooling solutions anda model to excel by continuous process improvements,
GIW is pumped for success for years to come.

SHAPE IT   Customer Report 16

From left to right, Stickel Production Manager Thomas Birkenmaier, OSG GmbH Technical Sales Representative Sven Clement and Stickel
Owner Matthias Stickel pose for a photograph at Stickel’s manufacturing facility in Löchgau, Germany.

Triple Benefits
OSG Phoenix PFB high precision indexable ball end mill boosts performance in metal
mold application with faster cycle, longer tool life and much improved surface quality
Magnus Hoyer
OSG GmbH
Located in Löchgau, Germany, Stickel GmbH is amanufacturer of sophisticated sheet metal parts
and assemblies made of steel, aluminum andstainless steel for prototypes, test construction
and serial production. Employing nearly 100
staff, Stickel is equipped with some of thelatest machines and facilities servicing majorinternational automotive manufacturers in Europe.
Stickel’s core competence is the production ofsmall and medium-sized structural components up
to 1,200 mm in length in areas such as the body,engine, chassis, no longer available spare parts for
expired series, and assemblies.
Stickel manufactures sheet metal forming partsin small quantity. The company also produces themolds for these workpieces. Due to the small lot
17 SHAPE IT   Customer Reportsize, the molds do not have to be hardened andcan be made from cast iron or low carbon steel
materials such as ST52. Although ST52 is easy tomachine, the tolerance of ingredients is very large.
Due to this nature, the work material can vary
greatly lot by lot, making it a major challenge for
Stickel to reach good surface quality at high feed
rates. The sheet metal parts are up to 1,200 mm
in length. The molds are measured at similar sizes
and are made of steel and cast iron.

The OSG Phoenix PFB is a high precision indexable ball end
mill engineered for superior surface finish and tool life. This
indexable ball end mill series is most ideal for 3-D finishing
operations where precision and surface finish are critical.
The PFB offers an array of inserts suitable for steel, stainlesssteel, cast iron, high hardened steel and non-ferrous metal
applications.

12

1. The OSG Phoenix PFB indexable ball end mill nearly tripled cycle time and doubled tool life while significantly improved surface quality in
Stickel’s metal mold application.
2. A completed metal mold by Stickel.

Stickel is an existing OSG tool user. During a recent visit
to the company’s manufacturing facility, OSG GmbHTechnical Sales Representative Sven Clement wanted
to help Stickel tackle the challenge of processing
improvement. Upon a detail evaluation of theapplication, Clement recommended the dia. 16 mm PFB
indexable ball end mill from the OSG Phoenix indexable
series.
The OSG Phoenix PFB is a high precision indexable ballend mill engineered for superior surface finish and tool
life. Its spiral cutting edge enables excellent cuttingedge strength and sharpness. The PFB’s steel andcarbide tool shanks help reduce chattering and provide
favorable milling surface when machining at short orlong overhangs. This indexable ball end mill series ismost ideal for 3-D finishing operations where precisionand surface finish are critical. The PFB offers an array of
inserts suitable for steel, stainless steel, cast iron, highhardened steel and non-ferrous metal applications.
Stickel’s molds are processed using a Hermle machining
center. The tolerance requirement for accuracy isapproximately 0.02 mm. The previous cutting tool wasused at a maximum feed rate of 1,500 mm/min. The PFB,
on the other hand, is capable of running at a maximum
feed rate up to 4,000 mm/min. By switching to the PFB
indexable ball end mill, Stickel is able to nearly triple
cycle time. Moreover, the durability of the PFB almost
doubled that of the competitor tool. Last but not least,
the surface quality has significantly improved to thepoint that some polishing processes can be eliminated,enabling Stickel to reach greater efficiency in their
manufacturing process.

Stickel’s core competence is the production of small and medium-sized structuralcomponents up to 1,200 mm in length in areas such as the body, engine, chassis, nolonger available spare parts for expired series, and assemblies. Images courtesy of Stickel.

SHAPE IT   Customer Report 18

2

3

1

4

1. From left, Kanagata Factory Manager Kittipong Sonsai and OSG Thai Sales
Representative Tantip Luangthongsri.
2. Kanagata Factory Manager Kittipong Sonsai.
3. Kanagata’s operator prepares for the machining of a mold.
4. OSG’s AE-BD-H carbide ball end mill and a high-hardness steel mold.

Superior Milling Solutionsfor High-hardness Steel
AE-BD-H and AE-LNBD-H carbide ball end mills enhance performance and consolidate
tooling in injection mold production
Tantip Luangthongsri
OSG ThaiFounded in 1989, Kanagata (Thailand) Co., Ltd. is amanufacturer of injection molding, injection molding machinesand cylinders for the plastic injection industry. A majorityof Kanagata’s products are associated to the Lion Group, aJapanese manufacturer of detergent, soap, medications, oral
hygiene products and other toiletries. Kanagata is responsiblefor designing and producing molds for the mass productionof these products. Kanagata is well-known in Thailand by
kitchen cleaning products in the name of the Lion Group and isregarded as one of the major mold-makers in the country.
Kanagata’s manufacturing plant is located in the Bang
Pakong district in the western part of Chachoengsao Province
in central Thailand. The company has over 50 employees
and operates in a 6,400-square-meter facility. Kanagata has
been manufacturing molds since the company’s founding
more than 30 years ago. On average, Kanagata makes
approximately 70 molds that are exported to Japan annually.
Kanagata utilizes a number of CNC machining centers in its
production, including Makino’s V33, V56 and V77 models,
DMG MORI’s NVX 5100, and Mazak’s Integrex 300-III.
19 SHAPE IT   Customer Report

5

6

7

5. Kanagata’s manufacturing plant is located in the Bang Pakong
district in the western part of Chachoengsao Province in central
Thailand. The company has over 50 employees and operates in a
6,400-square-meter facility.
6. A majority of Kanagata’s products are associated to the Lion Group,
a Japanese manufacturer of detergent, soap, medications, oral hygiene
products and other toiletries. Kanagata is responsible for designingand producing molds for the mass production of these products.
7. Founded in 1989, Kanagata (Thailand) Co., Ltd. is a manufacturer of
injection molding, injection molding machines and cylinders for theplastic injection industry.

Most of Kanagata’s applications involve high-hardness steel such as STAVAX (plastic mold steel), M300, NAK80, etc., with superior wear resistance andlifespan. However, the machining of these molds requires high quality tools to ensure precision, efficiency and overall cost performance.

Most of Kanagata’s applications involve high-hardness steel
such as STAVAX (plastic mold steel), M300, NAK80, etc.,with superior wear resistance and lifespan. However, themachining of these molds requires high quality tools toensure precision, efficiency and overall cost performance.
Kanagata was originally using milling tools from Taiwan andSouth Korea. However, the end mills were easily broken andhad short tool life. As a result, Kanagata had to use manyof the same tools in order to complete a part, making the
production very costly and time consuming.
Later on, Kanagata decided to test milling cutters fromvarious Japanese cutting tool manufacturers. The cutting
trial involved the machining of STAVAX using a DMG MORI
machining center running at a cutting speed of 8,500 rpm
and a feed rate of 1,550 mm/rev. The competitor tools
had trouble entering the workpiece and required longmachining time. OSG’s AE-BD-H (EDP number: 3042010)
and AE-LNBD-H (EDP number: 3056133) carbide end mills,
on the other hand, dominated the trial result with superior
accuracy and the best overall performance.
OSG’s AE-BD-H and AE-LNBD-H carbide ball end mills aredesigned to accommodate a wide range of applications
and milling methods in high-hardness steel with superior
performance. The AE-BD-H is a 2-flute carbide ball end
mill designed for high-precision finishing. It features avariable negative spiral gash for better chipping control.
The AE-BD-H’s superior ball R precision ensures a stableradius accuracy across 180 degrees. The AE-LNBD-H is a
2-flute long neck carbide ball end mill designed for highprecision finishing. Similar to the AE-BD-H, it also featuresa thick center core to help prevent deformation of the ball
tip to improve chipping control. Its teardrop-shaped outer
periphery strong back taper geometry enables milling by
point, which prevents chattering and chipping, resulting in
improvement of surface accuracy. This carbide ball end millseries is coated with OSG’s original DUROREY coating withsuperior heat resistance and high toughness optimized forhigh-hardness steel.
Kanagata was especially surprised by the performance of
OSG’s DUROREY coating, which enables the company toachieve higher cutting speed to save time. In addition tohigh accuracy, efficiency and reliability, the AE-BD-H and
AE-LNBD-H carbide end mills offer superior versatility that
Kanagata has not experienced before. Kanagata used toseparate tooling based on the type of work and material,
having to use many sizes of tooling in order to complete amold. By switching to the AE-BD-H and AE-LNBD-H, Kanagata
is able to consolidate tooling as they are able to excel inmixed tasks together. The end mills are also applicable tovarious materials, which further reduces processing time,enhances quality and performance of a mold.
Last but not least, the OSG Thai factory
is in close proximity to Kanagata,locating in the same Bang Pakong
district. When machining trouble arises,
OSG’s applications engineers and sales
representatives can quickly provide
assistance and troubleshoot.
“There are many tooling brands in thefield, but not all can offer the same quality
assurance as OSG,” said Kanagata FactoryManager Kittipong Sonsai. “When a single
tool is able to do it all, it is the right answer.”
The AE-BD-H and AE-LNBD-H 2-flute type carbide
end mills are ideal for high-precision finishing of
high-hardness steel with emphasis on machined
surface accuracy. By adopting OSG’s latest“DUROREY” coating ideal for high-hardness steel,high chipping resistance is made possible evenfor work materials exceeding 60 HRC, enabling
longer tool life.

SHAPE IT   Customer Report 20

AE-LNBD-NDLC Coated Carbide End Mill for Copper Electrodes

The AE-LNBD-N is a 2-flute long neckcarbide end mill designed for high-precisionfinishing of copper electrodes. Its unique ball
specifications include an optimal cutting edge
shape with excellent sharpness, high quality
primary relief surface, and superior ball R
precision that ensures a stable radius accuracy– all of which contribute to allowing highquality milling of copper electrodes

without burrs. The AE-LNBD-N is coated with
OSG’s DLC-IGUSS, a thick film type coatingthat suppresses wear on the cutting edge andachieves both high tool durability and goodmachining accuracy.

AE-MSS-H and AE-MS-H
Multi-flute Square Type and Radius Type Carbide End Mills for High-hardness Steels

The AE-MSS-H is a stub multi-flute carbide
end mill available in square style with a 1.5
x D length of cut (neck length of 3 x D). The
AE-MS-H is a short multi-flute carbide end
mill available in square and radius styles
with a 2.5 x D length of cut. The AE-MSS-H
and AE-MS-H feature unequal spacing teeth
geometry to suppress chattering duringmachining. Their optimal cuttingedge specifications allow forstable milling of highhardness steels.

21 SHAPE IT   Product Pickup

With the addition of OSG’s original DUROREY
coating, the AE-MSS-H and AE-MS-H are able
to exhibit outstanding performance in highhardness steels due to the coating’s excellent
toughness, high heat resistance and abrasion
resistance characteristics.

AM-HFC and PXHF-AMHigh Feed Radius Type Carbide End Mill and Exchangeable Head End Mill

The AM-HFC and PXHF-AM are engineered
to enable high feed milling of high-hardness
additive manufacturing parts. The PXHFAM is the exchangeable head version of
the AM-HFC and shares identical toolingspecifications. The AM-HFC and PXHF-AM
feature a composite radius cutting edge
optimized for flat surface milling. With a large
arc and corner R configuration, the AM-HFC
and PXHF-AM’s robust cutting edge is able towithstand shapes with unstable depthof cut. Moreover, the AM-HFC

and PXHF-AM’s flat cutting edge geometry
suppresses chipping of the end cutting edge
and enables good machined surface quality.
The AM-HFC and PXHF-AM include a coolant
hole to improve chip evacuation and prevent
chips from getting tangled.

AT-2
New Carbide Thread Mill Lineup for Rc and NPT Tapered Pipe Threads

OSG Corporation has recently expanded
its AT-2 carbide thread mill series for highhardness steels with a new lineup engineered
for thread milling Rc and NPT tapered pipe
threads. Six new items for Rc and six new items
for NPT have been added.
OSG’s AT-2 carbide thread mill is developed
to combine the drilling of a pilot hole andthreading into a single procedure even indifficult-to-machine materials such as highhardness steel. The AT-2 features a uniquehigh strength cutting edge shape tocontrol the bending of tool. It isengineered with a left-hand cut configuration
for climb milling to prolong tool life by
reducing tool deflection and the generationof heat. Roughing teeth are also added to
distribute tool load. Furthermore, the AT-2 iscoated with OSG’s original DUROREY
coating to suppress chippingin high-hardness steel
applications.

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OSG Corporation Hosts Die and Mold Web Exhibition
On April 1, 2021, OSG Corporation
launched a special online event – “OSG
Die & Mold Web Exhibition” on its
web showroom. The Die & Mold Web
Exhibition was held for a month from
April 1 to April 30, 2021. The latest
tooling innovations engineered for thedie and mold industry were displayed
virtually along with weekly webinars
that were hosted in collaboration
with partners from the manufacturingindustry.
The OSG Web Showroom is OSG Corporation’s
latest online exhibition website to provide
customers with a digital trade show experiencethat is not tied to time or place.

A special area named the “OSG Quest Die & Mold Dungeon”
was created to further engage visitors through gamebased learning. A new stage was released weekly with newcontents throughout the event period. On the site, visitors
could learn about die and mold applications, the latest
tooling innovations, attend webinars and win prizes bycorrectly answering a quiz at the end of the event.

A special area named the “OSG Quest Die & Mold Dungeon” wascreated to further engage visitors through game-based learning.

The OSG Web Showroom is OSG Corporation’s latest online
exhibition website to provide customers with a digitaltrade show experience that is not tied to time or place. OSG
offers a live chat feature (currently available in Japaneseonly) that allows its representatives to communicate withcustomers seamlessly. Visitors can discuss about tools andmachining with ease just like they would physically at an
exhibition booth. Live chat support is handled by OSG’stechnical staff who are experts in the field.

Scan to visit the
OSG Web Showroom

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1. On the site, visitors could learn about die and mold applications, the latest tooling innovations, attend webinars
and win prizes by correctly answering a quiz at the end of the event.
2. A new stage was released weekly with new contents throughout the event period.

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CIMT 2021
OSG participates at the 17th China International Machine Tool ShowThe China International Machine Tool
Show (CIMT) is recognized as one of thefour largest international machine toolshows in the world and is held in Aprilbiennially in Beijing. The 17th CIMT in
2021 took place at the China International
Exhibition Center (CIEC) from April 12 to 17
with approximately 1,650 exhibitors from27 countries and 125,500 visitors from 82
countries.
At CIMT 2021, OSG exhibited its toolinginnovations in a different approach than
before, shifting focus on application
solutions by exhibiting workpiece andcutting tooling as a set. For new products,
a QR code is included on all the displays toprovide visitors with easy access to productinformation.
The 18th CIMT show is scheduled to takeplace in April 2023.
The 17th CIMT in 2021 took place at the China International Exhibition Center(CIEC) from April 12 to 17 with approximately 125,500 visitors from 82 countries.

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1. A QR code is included on all the displays to provide visitors with easy access to product information.
2. OSG participates at the 17th China International Machine Tool Show in Beijing.

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OSG Around the World
Employee Interview withCorina Nichita
Corina Nichita
Location: Belgium
Position: Manager of Accounting at OSG Europe Logistics, OSG Belux,
OSG France and Managing Director of Romsan (OSG Romania)
Joined OSG: 1990
Motto: “A valuable person is a sum of accuracy, reliability and simplicity.”

gives employees the chance to prove that by dint of
hard work, anything is possible. It happens when you
believe, and you will persevere.

Tell us about your work and experience at OSG.
I joined OSG through the company’s acquisition of
AIMO Belgium in December 1990, more than 30 years
ago. It was a few months after my arrival in Belgiumfrom Romania, where I am originally from. My academic
background is rooted in economics, with specialties
in finance, business strategy, as well as organizational
planning and development. I studied at West Universityof Timișoara in Romania, where I gained my graduate
degree in economics. During my tenure at OSG, I have
served multiple roles including bookkeeper, IT manager
and general manager in addition to my current positionsas accounting manager and managing director.

Tell us about your daily routine.
When I am at the Belgium office, I start my day bydrinking a cup of tea prepared by one of my colleagues.
It has become a ritual that I hold dear. Depending on
the accounting deadlines (monthly, annual closing,consolidate reporting, budget plan, etc.), I share andbring my contribution to the work of my accounting
colleagues. Their performance, attitude and way
of work make this ‘task’ very easy and not timeconsuming, which allows me to complete other actions,
responsibilities and to attend miscellaneous meetings.
When I am at the Romsan office in Romania, I would
start my day around a coffee meeting with the global
team. I would review tasks revolving human resources,
operation, supervision of the commercial and technicalstrategy, as well as budget management.

Accuracy, reliability and simplicity are the principlesof my work ethic. An accountant must disclose to
management, give them confidence in the accuracy
and rightness of the figures provided. Moreover, being
trustworthy and performing well regularly is thefoundation of successful teamwork as no one achieves
greatness on their own.
It is hard to imagine having a 30-year career in thesame company with work remaining pleasant everyday. At OSG, it is possible, and it is very gratifying. OSG
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Front left, Nichita poses for a group photograph with her
accounting team at OSG Europe Logistics in Belgium.

1

2

1. Center seated, Nichita poses for a group photograph with her colleagues at Romsan in Romania, where she serves as managing director.
2. Nichita visits a salt mine in Romania. Nichita is originally from Romania and moved to Belgium in 1990.

What is most challenging about your work?
It is challenging to encourage individuals to set goals;
and to act as a source of encouragement to one another.
I strive to share my experiences with multicultural teams,
giving them the will to push further, to try something
new and to improve themselves.
What is unique about OSG Europe?
Being the headquarters of the European region,
working at OSG Europe offers the opportunity to workand collaborate with many representatives and top
management from the OSG Group. It is a pleasure to beable to work with dedicated senior employees as well as
the younger generations who are full of energy and new
initiatives. Since we work very closely with the corporate
headquarters in Japan, it is also very enjoyable to work
together with our Japanese colleagues, exchange values
and getting inspired.

What is your favorite OSG tool?
Skiving cutter is my favorite tool. It is a productthat demonstrates the ability and vision of OSG todevelop and create new manufacturing solutions.
The first test and implementation were realized by
OSG Romania, Romsan. Without the involvement andtechnical support of the company headquarters OSG
Corporation, it would not have been possible. With
support and trust from the parent company, newtooling concepts can continue to evolve and improve.
In addition to standard items,
OSG also offers custom toolingsuch as skiving cutters, which
are used for manufacturing
internal gears. Gear shaping byskiving is a continuous cutting
process that is highly efficient.
With a single setup, skiving offers
higher productivity, flexibility andimproved quality than broaching.

How do you spend time on your day off?
I enjoy hiking on Sunday mornings with friends, taking
care of my garden, and doing workouts. I especiallyappreciate spending time with good friends, raisinga glass, sharing a nice meal and simply enjoying the
moment.

Nichita taking a hike at the Machu Picchu insouthern Peru. On her day off, Nichita enjoys
hiking, gardening and working out.

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