Customer Testimonial: Micro Technology

Pictured from left to right: Ted Pierce– Shop Foreman/ CNC Programmer; Charlie Wright, Jr. – General Manager; John Hargrove- Lead CNC Setup/Operator

Pictured from left to right: Ted Pierce, Shop Foreman/CNC Programmer; Charlie Wright, Jr., General Manager; and John Hargrove, Lead CNC Setup/Operator

 

The U.S automotive industry has experienced rapid growth for the last several years. In 2015, US auto sales hit a record high. According to DeBord, cheap gas and easy credit as well as the low unemployment rate contributed to the booming auto sales. The demand for reliable and high-tech cars has increased.

 

In order to keep up with this increasing demand, U.S. auto manufactures have been strict about meeting customers' time constraints. Efficiency and productivity has become essential more than ever for both of the auto and the auto parts manufacturers.

 

Micro Technology is an auto parts manufacturer located in Tullahoma, TN. After years of experience as a machinist, the owner, Charlie Wright Sr. started the company in 1987 with just 3 mills, 3 lathes, 1 radial arm drill and 1 brand saw. After 30 years, his son, Charlie Wright Jr. is in the process of taking over the company.

 

The company mainly produces parts that are used to mount to automotive engine blocks to be robotically transported through assembly lines. They produce various models and quantities annually and these parts are 2-part sets which are machined and then assembled requiring additional time before shipping out to the customers. While the soon to be new owner, Wright Jr., focuses on quality and accuracy of his products, he also strives for improved efficiency and productivity. He was looking for ways to cut machining time to meet strict time constrains of his customers, so he reached out to DGI and OSG's district manager, Philip Woody.

 

The company uses HAAS VF-3 with CAT40 taper tools. The part being machined is 6061 Aluminum and the tolerance requirement is +/- 0.002" to achieve the precise geometry and finish the company needs. Wright Jr. used to machine the parts with a competitor's face mill which ran at 3,000RPM 120IPM with 1.25" axial and 1.2" radial depth of cut. He wanted to improve productivity without sacrificing quality and accuracy.

 

Woody recommended OSG's PHOENIX® PRC indexable radius cutter (EDP #7800404) with 12mm diameter aluminum grade insert (EDP# 7811013.) The PRC ran at 5,780RPM 345IPM surpassing speeds and feeds of the competitor tool. The company was able to cut the machining time by roughly 25 minutes per part achieving a 50 minute reduction per set! In addition to the machining time, the company was able to improve the surface finish with OSG's PRC. 

 

"This tool [the PRC] was extremely instrumental in achieving our required tolerances and meeting delivery deadlines of my customers," said Wright Jr.

 

Wright Jr. is excited for his new journey as an owner with the reliable tools from OSG and Woody is walking alongside with him to support his needs and to reach even greater heights.

 

Source:

DeBord, Matthew. (2016, December 21st). The US auto industry may surprise everyone in 2017. Business Insider. Retrieved from http://www.businessinsider.com/us-auto-industry-growth-in-2017-2016-12

 

OSG Announces Release of Additions to the OSG Phoenix® Line!

OSG PHOENIX® PFR Finishing Radius End Mill series:

 

The following list numbers are associated with the PHOENIX® PFR products:

List 52200 -- PHOENIX PFR inch end mill bodies

List 78320 -- PHOENIX PFR metric end mill bodies

List 52605 -- PHOENIX PFR inch screw fit bodies

List 78220 -- PHOENIX PFR metric screw fit bodies

List 78PFR -- PHOENIX PFR inserts


What's new?

  • Added Ø0.250" end mill bodies and inserts
  • Added Ø6mm end mill bodies and inserts
  • Added 2.5 L/D Ratio steel shank end mill bodies

 


OSG PHOENIX® PXMC Collets for the PHOENIX® PXM Exchangeable Head End Mill series:

 

The following list numbers are associated with the PHOENIX® PXMC products.

List 78340 -- PHOENIX PXMC collets


What's new?

  • PXMC collets are available in short and extra-short versions
  • PXMC collets are compatible with OSG's HY-PRO Shrink 2pc Base Holders
  • PXMC collets dramatically reduce overhang length to greatly improve milling rigidity & balance
  • PXMC collets are ideal for use in small machining centers

 

Please visit our website for product information, pricing and availability.

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!



Stable and Efficient Milling with OSG PHOENIX® Indexable Tools!

Are you struggling with unstable machining with your indexable tools? Higher cutting force is one of the main causes of vibration and instability. You want to achieve lower cutting force to prevent vibration, but you are also looking for ways to improve productivity. OSG’s PHOENIX® PSE (90° indexable shoulder cutter) and PHC (indexable high feed cutter) offer solutions that not only provide lower cutting forces and better productivity, but also enhanced rigidity and improved quality of your finished parts. 


Many conventional shoulder mills have difficulty with ramping and helical milling operations due to their design. OSG's PHOENIX® PSE enables productive ramping and helical milling with the insert's bottom notch feature. The PSE's cutting geometry also generates lower cutting forces, and the insert's wiper edge produces superior surface finish. PSE is a multi-purpose cutter that can tackle a wide range of applications including facing, side milling, slotting, ramping and helical milling! Watch PSE in action!



If you have specific needs for a rough milling application and achieving high metal removal rates, our PHC is the go-to tool for you. A combination of sharp cutting edge and high feed cutting edge design makes it possible to achieve productivity and low cutting force even with overhangs! PHC’s economical 4-corner insert with a chip breaker enhances cutting performance while maintaining rigidity. Watch PHC in action!





For a limited time only, you can save on our high performance indexable milling cutters. Take advantage of our amazing deals to achieve stable milling! Click HERE to learn more about the deals!



OSG New PHOENIX® Catalog for High Performance Indexable Drilling and Milling




We have introduced our highly anticipated OSG PHOENIX® Vol.4 catalog in print and digital versions!

 

The latest catalog edition is over 150 pages and features new products and many expansions to existing quality lines of indexable milling and drilling. Notable additions to the milling lineup includes 45° face milling cutters, screw fit end mills, and replaceable head end mills. Indexable drills and replaceable head drills also have been added to the drilling offering.


Click here to view the catalog!