OSG Introduces the New EXOCARB® ADF Drills!

 

We announced the release of our new EXOCARB® ADF drills. The ADF combines two operations in one for the drilling of inclined surfaces and counterboring applications.

 

The ADF was developed with an “all-purpose” concept for superior versatility, reliability and quality for flat-bottom holes. Machining a flat hole traditionally required the use of an end mill and a drill. The ADF enables one-step drilling thereby simplifying machining time and tool management. The drill’s balanced point form improves precision and minimizes the shifting of hole position. Its sharp cutting edge results in low cutting force to minimize burrs even in thin plates. With a wide chip room geometry, trouble-free chip evacuation can be achieved. Furthermore, with the addition of OSG’s new proprietary EgiAs coating, tool life can be prolonged with excellent heat and wear resistance.

 

The ADF is engineered for a wide variety of drilling applications including inclined surfaces, curved surfaces, counterboring, eccentric holes, thin plates, etc. It is suitable for common materials such as carbon steel, alloy steel, hardened steel (up to 35 HRC) and cast iron. Standard types are available in diameters from 2 to 20 mm; long types are available in diameters from 3 to 20 mm).

 

Reaming Composites Made Easy with the EXOPRO® AERO-D-REAM!




Are you having issues with peel-up, thrust and delamination when drilling or reaming carbon and glass fiber composites? These composites are constructed with layers of material that are prone to delamination. You are probably having problems with your tool life as well. Carbon fiber is known to be abrasive, and could easily wear your tool down. If your tool loses its sharpness, it pushes the material away instead of cutting, producing uncut fibers. This forces you to continually monitor your tools while machining.


With OSG’s EXOPRO® AERO-D-REAM, you can machine carbon and glass fiber composites without worrying about tool life. The AERO-D-REAM features OSG’s patented diamond coating which significantly improves tool life and hole quality. The coating has a maximum diamond grain size diameter of 2μm. This strictly controlled diameter allows our coating to be super smooth and extremely sharp! We also utilize grinding techniques on our special carbide substrate which prolongs tool life.


When the AERO-D-REAM was compared to its uncoated counterpart, it was able to drill 14 times more holes and provided better hole quality. At 180 holes, it did not show any signs of margin wear!


In addition, the AERO-D-REAM has a tapered-4-flute design to limit peel-up at hole entrance as well as elongated double-angle geometry to reduce thrust and limit exit delamination.


Sounds too good to be true? We are currently offering promotional deals to save up to 15% on our aerospace tools including the EXOPRO® AERO-D-REAM! Click here to learn more about our deals.

Case Study: Down time is the time to improve efficiency and productivity


Current Situation


David Whitmire, OSG district manager, has been covering a sales territory in Texas and Oklahoma for 9 years. He has witnessed both the best and worst days of the energy industry. Since the price of oil per barrel has recently reached record lows, our economy and oil field manufacturers have been severely affected. An increasing number of layoffs and downsizing at companies has occurred in the area. During this down time, some oil field manufacturers started to do their homework by reconsidering their machining processes as an avenue to cut costs. This has opened up some new opportunities for OSG in David’s territory.


One of David’s customers is a large pump housing manufacturer in the oil field industry. During the industry slowdown, the company wanted to be proactive, so they invited OSG and a local distributor to host a tap trouble shooting seminar. During the seminar, David showed them the OSG EXOTAP® A-Tap® and EXOPRO® Mega Muscle® drill videos. These videos drew a lot of attention as they showed A-Tap® and Mega Muscle® products surpassing speeds and feeds of competitors’ tools. This company produces 50 to 60 parts after spending over 625 hours machining per month. David decided to perform tool testing with his local distributor to help the company improve productivity and cut costs.


Tool Testing/Solutions


Material: 4140 Modified Alloy Steel


1. ¾-10 EXOTAP® A-Tap® (18 SFM) vs. Competitor A’s tap (18 SFM)


2.
1 ¼-7 HY-PRO® VXL Tap (30 SFM and 13.1486 IPM) vs. Competitor A’s tap (23 SFM and 11.0 IPM)


3.
1 ½-6 HY-PRO® VXL Tap (30 SFM and 12.5 IPM) vs. Competitor A’s tap (23 SFM and 10.0 IPM)


4.
½-13 EXOTAP® A-Tap® 50 SFM and 29.3758 IPM vs. Competitor A’s tap (13 SFM and 7.692 IPM)


5.
7/16” EXOPRO® Mega Muscle® Drill (325 SFM and 48.2 IPM) vs. Competitor B’s Cam Drill (8.2 IPM)


6.
7/15” EXOCARB® WDO® Drill (325 SFM and 28.4 IPM) vs. Competitor B’s Cam Drill (2.5 IPM)


7.
22mm PHOENIX® PXD Exchangeable Head Drill 300 (SFM and 21.2 IPM) vs. Competitor B’s Cam Drill (2.8 IPM)


Results


Test 1 demonstrated a significant advantage of the A-Tap®. Even if it ran at the same speeds and feeds with the competitor’s tap, the A-Tap® was able to produce 25% to 40% more pump housings and to reduce costs by $22 per tool versus the competitor’s tap.


Tests 2, 3, 4 and 5 showed that OSG’s taps and drills ran at faster speeds than the competitors’ tools, and the A-Tap®, VXL Tap and Mega Muscle® products were able to reduce the cycle time by 23 minutes. In addition, the A-Tap® and Mega Muscle® machined 5 times more parts than the competitors’ tools did.


Tests 6 and 7 have not been completed, but David is confident that the WDO® drills and PXD drills will reduce the cycle times even more. By using OSG’s taps and drills in their operation, David predicts that the company will be able to reduce at least 21 hours of machining time per month!



The EXOCARB® WDO-SUS Drill Video: Meet the Game-Changer for Stainless Steels & Titanium Alloys


What are the common issues you encounter while machining stainless steels and titanium alloys? You name it and OSG’s new EXOCARB® WDO-SUS drills will tackle it!

 

The WDO-SUS drills are specifically developed to combat work hardening, elongated chips, low thermal conductivity and welding on the tool. Watch the video below to learn more about the premium features of the WDO-SUS drills including the newly designed MEGA COOLER™ coolant holes.



Tim Holmer to Present at Aerodef


One of our very own, Tim Holmer, will be hosting a presentation at AeroDef on April 22, 2015 titled “Composite Drilling—In Slow Motion.” AeroDef is the aerospace industry’s most acclaimed manufacturing event, featuring the leaders in commercial and defense aerospace manufacturing.


“Composite Drilling—In Slow Motion” is an experiment using high-speed video to show the effects of several drilling geometries in a variety of structural composites.  Attendees will learn about the challenges of drilling composites and the effects on hole quality. Common issues such as uncut fibers and delamination can be seen in a new perspective with the video visual aid, and tips on how best to avoid them will be explained. The information provided will help assist in proper selection of drill geometry for specific types of composites.


Tim has been providing customer support for various industries as an Applications Engineer for two and a half years. Before joining OSG, he graduated from Wright State University with a Mechanical Engineering degree.


Beyond his engineering expertise, Tim is experienced in public speaking, having presented at IMTS 2014 in Chicago, at various customers’ locations, and internally at OSG. After recently taking a more of active role in the Aerospace Industry by testing tools for new applications in our R&D Facility, Tim is ready to share his newest project with the AeroDef attendees.


Tim’s presentation will begin at 10:55AM on April 22nd in Coronado B (located on the lobby floor of the West Wing) during the Machining & Drilling of Composites session. Before or after the session, be sure to stop by OSG’s booth# 434 to check out our many drilling geometries, and more, that we have to offer.


WHO-Ni Drill, WHR-Ni Tap, UVX-Ni End Mill - Total Solution Video

When tapping, drilling, and milling heat resistant super alloys like Inconel 718, you need tools that can take the heat. OSG provides a total solution tooling trifecta for these tough machining applications.  With the rigid substrates, tailored geometries, and advanced coatings on our EXOPRO® WHR-Ni Taps, EXOPRO® WHO-Ni Drills, and EXOPRO® UVX-Ni End Mills, you can tap, drill, and mill without the worry of rapid wear or extreme breakage.


Check out these tools at work:




EXOPRO® WHO-Ni Drill Video

The EXOPRO® WHO-Ni drill series from OSG can take the heat when processing Nickel Alloy, Inconel 718 and other hardened steels.


These high performance drills incorporate OSG’s exclusive WXS nano-coating, which has been developed specifically for high heat applications. Internal coolant holes offer further heat resistance and chip evacuation, while a slow helix angle provides ultimate rigidity with minimal wear even after hundreds of holes.




EX-SUS-GDR Drill Reduces Cost per Part on Stainless Steel Exhaust Header

Darrel McCoy, District Manager

The 41st Annual Barrett-Jackson Auction located in Scottsdale, AZ. is no ordinary auction. It is “The World’s Greatest Collector Car Events™,” which captures the essence of a passionate obsession that collectors and enthusiasts share throughout the world. I was fortunate enough to attend the auction where I saw lines of gorgeous vehicles and watched a $50,000 bid shoot up to $250,000 in 30 seconds, all for a used car!

Many of the high performance vehicles displayed in the auction had employed the exhaust manifold design, also known as the exhaust header design, for car tuning. Exhaust headers are one of the easiest 
bolt-on
 accessories
 for improving
 engine 
performance because they make
 it easier for
 the engine to
 push exhaust
 gases out of 
the cylinders. Most headers 
for naturally aspirated
 engines are 
manufactured 
in mild steel, while headers for turbo charged engines, on the other hand, are often manufactured in 304 Stainless Steel.


Recently, one of my customers from Las Vegas, NV, who is a header plate manufacturer, called regarding a drilling operation in 304 Stainless Steel. He had been using standard cobalt drills but was not able to produce a good hole and had encountered some abnormal sound during the operation. To solve the problem, the customer had to pay to water jet at $40 
per part. Not only were they losing money, they also had to extend their lead-time by using an outside vendor.


After a careful examination of the application, I recommended OSG’s EX-SUS-GDR drill from the EX-GOLD® series. OSG’s EX-SUS-GDR drill is manufactured from premium high-speed steel, ideal for stainless steels, mild steels and aluminum alloys. The addition of OSG’s TiN or TiALN coating improves wear-resistance and prolongs tool life.

During the first test, the EX-SUS-GDR drill also encountered the abnormal sound, producing a long thick chip and breaking after the second hole. I was concerned with the chip formation while the customer was concerned with the sound, breakage and no parts. I knew that once we had the chip formation under control, the sound and tool life would increase. So, starting off slow, we increased the 10 mm EX-SUS-GDR drill to 480 RPM with 0.009 IPR. With these simple adjustments, we were able to produce 120 holes and finish the job with no trouble whatsoever.


At the end of the day, this customer was not only able to produce holes efficiently and effectively, but they also eliminated the need to utilize an outside vendor, reducing lead-time and cost per part.


The success of large auto events like the 41st Annual Barrett-Jackson Auction depend on having consistent, working parts in all of their cars. By using our EX-SUS-GDR drill combined with the right cutting tool strategy, our customer was able to produce parts more efficiently, allowing them to continue to supply cars with headers that hold up under the spotlight.



WDO Drill, XPF Tap, VGx End Mill - Total Solution Video

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.




HELIOS® Drill: No Pecking or Coolant-Through Required

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.