15. October 2014
Mike Harris, District Manager
In manufacturing, components that contribute to
success often include quality, precision and fast production at minimum cost.
This equation sounds simple, but can be difficult to achieve for some machine
shops. In the medical industry, manufacturers often handle difficult-to-machine
materials such as titanium and stainless steel. Tooling costs could skyrocket
if the appropriate tool isn’t selected for
Recently, I received a call from a national
distributor that has an integrated supply contract with a large OEM medical
in Warsaw, Indiana. This customer is one of the world’s leading
designers, manufacturers and suppliers of orthopedic implants. They offer
devices and solutions for fixation and fusion, motion preservation,
In producing the parts for one of these implants, the customer needed a better tapping solution than what they were currently using. They were specifically tapping 6-32 threads in Ti-6Al4V but were running through taps like water, getting between 20 to 50 holes per tap and using over 75 taps per month. Despite trying and testing a variety of different brands, none were successful in significantly lowering the number of holes per tap.
I sat down with them and reevaluated the process, hole size, hole quality, cutting speeds, depth of drill vs. depth of thread, tool holders, work piece holding and coolant. Everything looked good, so I knew the tap had to be the key to solving this issue and I knew just what product to recommend.
I suggested they try the EXOTAP® VC-10
TI Taps from OSG. These ultra-premium taps are made from a VC-10 Powered Metal High Speed Steel substrate, which offers longer tool life in Titanium and other hard materials. Plus the OSG V-coating provides increased hardness, lubricity and wear resistance, further prolonging tool life. I sent the customer a few sample taps and they said they would get them tested right away.
The following week I got in touch with them and they happily informed me that the tap was still running. They ultimately went down from approximately two taps a day to two taps a week! This drastic reduction has saved them both money and down time on the shop floor.
The EXOTAP® VC-10 TI tap has proven to me that with the help of the right cutting tool, customers can reduce tool usage and drastically minimize tooling costs. When no other tap can do the job, work the VC-10 TI tap into the equation. It is the industry solution for those difficult materials and applications.
The versatility of the EXOCARB® WDO Drills, EXOPRO® XPF Taps and HY-PRO® VGx End Mills makes this dynamic trio an unstoppable force.
Whether drilling, tapping or milling, the unique design of these tools allows them the ability to machine a wide range of materials from cast aluminum and carbon steels to die steels and hardened materials, making them an ideal solution for job shops and manufacturers requiring flexible tooling options.
22. September 2014
OSG had a ROARIN’ good time yesterday at the Brookfield Zoo 5k, Zoo Run Run, to benefit the Chicago Zoological Society’s Conservation Fund. Twenty-one runners strong, this is the third 5K run/walk of the season for the OSG Runners Club.
Instituted over two years ago, the Runners Club has been growing in popularity among OSG employees with about 70 employees and their family members participating this year alone. This is the largest group since the club’s inception.
As part of the OSG Wellness Campaign, OSG covers the cost of registration for up to four running events per year. The group holds a meeting at the beginning of each year to choose which races to participate in, doing their best to include some local races, races that support a charitable cause and races that allow you to run or walk.
Celina Perez, HR Payroll Coordinator and head of the Runners Club, said the races help to promote wellness and team building amongst employees and their families.
“Some people join the club to improve their health…others might want to reduce stress or just enjoy the fun of running.” Celina added, “I really enjoy getting together with other OSG employees outside of work and enjoy either running or walking with everyone. It’s a good time.”
So far this year, OSG employees and their families have participated in the Glo Run 5K in Chicago, IL, the Run for Hunger 5K in Elmhurst, IL and the Zoo Run Run at Brookfield Zoo in Brookfield, IL. The club will round out the year at the Hot Chocolate 15K/5K in Chicago, IL on November 9.
18. September 2014
We have introduced our highly anticipated 2014 Cutting Tool Solutions Catalog in print
and digital versions.
catalog edition is 1200 pages and features new tap products including the
EXOPRO® CC-SUS, EXOPRO® WHR-Ni and EXOTAP®
A-TAP®, the EXOPRO® PHX End Mills, and many expansions to
existing quality lines such as the EXOCARB® WXL® and WXS®
premium performance carbide end mills, EXOPRO® Mega Muscle and
EXOCARB® WDO® Drills.
addition to the catalog is the new Composites section that lists OSG's top tier
of high performance tooling for CFRP and CFRP stacks.
Cutting Tool Solutions Catalog can be accessed digitally here or you can
request a free hard copy using the Literature Request Page.
17. September 2014
Featured employee: Vicki Stevic
Title: Production Control Supervisor
Tenure with OSG: 19 years
If there’s one thing that Vicki’s tenure with OSG has taught her, it is that hard work and dedication do not go unnoticed. But those things do not stop at the doors of OSG for Vicki. With her main focus being her three children and raising them to stay on the right track, she recognizes how much discipline and organization it requires to neglect neither work nor her family.
Vicki admits that her mom is her true hero, looking to her for inspiration. “She came to the United States at the age of 18 after marrying my father without any family of her own. She learned the language, raised two children and ran the household, always while working a full time job. She is an amazing woman, wife, grandmother, mother and friend.”
Although Vicki’s personal goal is to live a healthier life through food and exercise, her passion will always be her family.
3. September 2014
David Whitmire, District Manager
There are many things that can hold job shops back,
from tight tooling budgets to non-coolant through machines. On a recent visit to a customer located in
Overton, TX, the owner of a medium sized job shop had expressed a major concern
regarding one of his drilling operations.
The OSG solution easily solved both these issues and more.
The customer was trying to drill a 7/16” diameter
hole, 9” deep in alloy steel using a competitor’s high-speed steel drill,
running at 525 RPM and a feed rate of 0.003 IPR. With that tool, at those
parameters, they were pecking
every 0.050” to get the
chips out of the hole, which added considerable time to the process; it was taking
approximately 22 to 25 minutes to drill just one hole.
Based on the cutting
conditions and the trouble they were having with pecking, I knew that
this was a great application for the OSG HELIOS® Drill. OSG’s
V-Series HELIOS® drill is a high-speed,
cobalt drill designed for
deep-hole drilling. The
unique design and patented technology
of this drill gives it the
ability to process deep holes without the use of internal coolant supply.
State-of-the-art flute design
improves chip evacuation, making it feasible to drill up to 20D without pecking.
By utilizing OSG’s WXL®
coating, the V-Series HELIOS® drill can handle a wide range of materials with up to three
times greater wear
resistance versus conventional coatings.
Upon explaining the benefits of this high performance drill, informing the customer that we had a HELIOS® 7/16” x 20D drill available off the shelf with the required flute length and that we could run it at 837 RPM and 0.008 IPR, he immediately ordered two test drills.
As soon as the drills were delivered, I received a call from the machine operator wanting to verify the speeds and feeds before running the drills. After I confirmed that 837 RPM and 0.008 IPR was indeed accurate, his first comment was that he didn’t think the HELIOS® Drill would make it through one hole, but he proceeded with the testing based on those parameters.
When the operator couldn’t hear any noise on the first hole, he was sure the drill was already broken, but to his amazement, the drill was still in the machine when the cycle ended. Even then, the operator continued to be skeptical. It wasn’t until the HELIOS® drilled 100 holes and all the parts were completed that he was finally sold on this dynamic drill. The operator himself admitted that the HELIOS® Drill had dramatically reduced cycle time and saved three days of machine time alone.
When all was said and done, by eliminating all the pecking required with the other drill, we reduced the total drill cycle time from 25 minutes to 1.5 minutes per part. This didn’t even take into account the cost savings, which was estimated to be nearly $30,000 based on the 5,000 holes the shop was scheduled to drill.
OSG’s HELIOS® drill was able to help this customer improve their machining process and produce more parts off the machine per day. Plus, the HELIOS® Drill is a fraction of the price compared to solid carbide drills, making it a more economical solution with the flexibility to be used on non coolant-through machining centers.
29. August 2014
Featured employee: Meghan Zimmerman
Title: Marketing Assistant
Tenure with OSG: 2.5 years
Having been with OSG 2 ½ years now, Meghan has learned a great deal from her previous experience in customer service and her participation in continuous training classes offered by OSG.
But when Meghan is not exercising her mind at work, she enjoys small weekend getaways with her husband, especially anything involving the great outdoors.
From horseback riding to long walks and bike rides through the forest preserves of DuPage, Cook and Lake Counties, she delights in the fresh air and tranquility that comes from being one with nature.
“It’s our favorite hobby in the fall months as the leaves turn to brilliant colors of yellow, orange, red and purple.”
Meghan also enjoys drawing natural landscapes as well, finding it has a calming effect, but her other true passion is animals. With a unique infatuation for dogs, cows and horses, Meghan would one day love to complete her Bachelor’s Degree in Animal Science.
18. August 2014
OSG was featured on the cover of the August issue of MoldMaking Technology. National Corporate Product Manager, Roger Goble, provided the corresponding feature article on a new approach to machining deep 3D cavities and cores which dramatically reduces cycle time in comparison to traditional EDM methods.
Read the full article here*.
*This article originally appeared in the August 2014 issue of MoldMaking Technology. It is reproduced here with permission from the publisher.