OSG Announces the Release of A Brand A-Drills!

 

 

A Brand is OSG’s premium tooling brand that represents the quality assurance OSG guarantees to each and every customer. A Brand products (A-Drills, A-Taps and A-End Mills) are designed to exceed the evolving manufacturing needs of our customers. The A-Drill series features EXOCARB® AD, ADO, ADO-SUS and ADF. Experience the level of quality, reliability and satisfaction that can only be delivered by OSG’s A Brand tooling master class!

 

EXOCARB® AD & ADO 2D-30D

 

The EXOCARB® AD & ADO feature superior point strength with low cutting force are achieved to accommodate a wide range of carbide drilling applications. EgiAs coating constructed with extreme toughness, high wear and heat resistance characteristics ensure stable and consistent tool life. The EXOCARB® ADO offers a coolant-through option for those with coolant capabilities.

 

AD & ADO Features

 

  • EgiAs Coating for exceptional wear resistance and toughness
  • Coolant-Through (ADO) for longer tool life and smooth chip evaluation
  • Optimized Drill Geometry For Every Drilling Depth
    • Wavy Point Form (2D-8D) reduces thrust and torque while creating smaller more manageable chips
    • Straight Point Form (10D-30D) enhances cutting edge strength while reducing cutting forces
    • Wide Flutes (2D-8D) facilitates stable chip evacuation
    • Middle Margin (8D-30D) improves stability in deep-hole applications

 

AD Line-Up

 

 

ADO Line-Up

 

 

EXOCARB® ADO-SUS 3D & 5D

 

Work hardening, welding, elongation of cutting chips and poor thermal conductivity are common problems in the machining of stainless steels and titanium alloys. The ADO-SUS is a carbide drill series that employs a unique coolant hole shape and tool geometry to enable efficient drilling in these difficult-to-machine materials.

 

ADO-SUS Features

 

  • Patented "MEGA COOLER" Coolant Holes drastically increase coolant flow, suppressing heat generation and enhancing chip evacuation
  • Patented Flute Geometry forms ideal chips for efficient chip evacuation
  • Patented Cutting-Edge Geometry reduces work hardening
  • WXL Coating provides superior heat and wear resistance for long tool life

 

ADO-SUS Line-Up

 

 

EXOCARB® ADF 2D

 

Machining a flat hole traditionally required the use of an end mill and a drill. The EXOCARB® ADF enables one-step drilling to simplify machining time and tool management. Suitable for a wide variety of drilling applications including inclined surfaces, curved surfaces, counterboring, eccentric holes, thin plates, etc.

 

ADF Features

 

  • EgiAs Coating for exceptional wear resistance and long tool life
  • Wide Flutes for superior chip evacuation
  • Balanced Point Form for reduced thrust and improved stability
  • Improved Cutting Edge reduces cutting forces and creates smaller chips

 

ADF Line-Up

 

 

 

Watch our A Brand video on YouTube!

 

OSG Announces Release of OSG EXOTAP® VC-10 & VA-3 Coolant-Through Taps

We are pleased to announce the release of OSG EXOTAP® VC-10 & VA-3 Coolant-Through DIN length Taps for Difficult to Machine Materials and Stainless Steel.


The following list numbers are associated with the EXOTAP® VC-10 & VA-3 products.

  • List 317TI - EXOTAP® VC-10 Ti Oil DIN SFT Inch sizes
  • List 348TI - EXOTAP® VC-10 Ti Oil DIN SFT Metric sizes
  • List 317 - EXOTAP® VC-10 Oil DIN SFT Inch sizes
  • List 351- EXOTAP® VC-10 Oil DIN SFT Metric sizes
  • List 307- EXOTAP® VC-3 Oil DIN SFT Inch sizes
  • List 347 - EXOTAP® VA-3 Oil DIN SFT Metric sizes
  • List 316TI - EXOTAP® VC-10 Ti Oil DIN POT Inch sizes
  • List 347TI - EXOTAP® VC-10 Ti Oil DIN POT Metric sizes
  • List 316 - EXOTAP® VC-10 Oil DIN POT Inch sizes
  • List 350 - EXOTAP® VC-10 Oil DIN POT Metric sizes
  • List 306 - EXOTAP® VC-3 Oil DIN POT Inch sizes
  • List 346 - EXOTAP® VA-3 Oil DIN SFT Metric sizes

 

This series offers the following:

  • V Coating for increased harness, lubricity & wear resistance
  • Expanded the VC-10 series offering to include both coolant-through and DIN
    overall length options
  • The VC-10 series has unique geometries to excel in titanium or other difficult to
    machine materials as does VA-3 which excels in Stainless Steel.
  • The VA-3 features HSSE Substrate for increased wear resistance.

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.

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).

 

Orthodontics Made Easier

By Dustin Loschiavo, District Manager

 

 

Did you know there are twice as many people wearing braces today than there were 15 years ago? The need for the new and improved orthodontic products has grown rapidly.  I recently visited American Orthodontics in Sheboygan, WI, one of the largest Orthodontics manufacturers in the world. They have just introduced the PowerScope, a wire to wire device that eliminates the need for headgear and special bands with more comfort and a better aesthetic appearance.

             

                                          

I spoke with Lee Vogel, Manufacturing Engineer at American Orthodontics, who expressed that they were having a problem with tool life on the right and left side tower mounts. They had recently changed materials per the customer’s request from a 316 stainless steel to a 17-4 stainless steel to extend the life of the device. The machining process involved milling a flat on two sides of round stock using a Citizen bar-feeder lathe. They were using a competitor’s 1/8 – 1/8 – 1/4, 1 ½ 4 fluted end mill. This end mill was taking 10 passes per side running at 4500 RPM and a feed rate of 8 IPM. I suggested that Lee should take less passes and test OSG’s Aero UVX end mill (3/16 – 7/16 - 0.015 CR 4 flute) for his new material application. We set up at 4 passes per side running at 5000 rpm and a feed rate of 16 IPM.  This change alone saved 11 seconds per part and the tool life went from 1600 pieces to 6000 pieces per end mill.

 

 

As the number of people with braces is expected to increase more in the near future, manufacturers need to keep up with the trends and demands for the improved braces by coming up with new innovations. In order to do so, it is crucial to be flexible and ready to machine any new materials with efficiency. OSG’s Aero UVX end mills changed the game of machining 17-4 stainless steels with efficiency and extended tool life.

 

*This article originally appeared in the OSG Cutting News Magazine 2015 Medical Edition.

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!



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.



The EXOTAP VA-3® Now Available with Coolant-Through!


For any manufacturer, time is money, and an increasing number of companies are looking for ways to improve efficiency in their manufacturing process. In order to support such demand, OSG improved its popular tap series, the EXOTAP VA-3®.  The EXOTAP VA-3® already excelled in both stainless and carbon steels, but now you can tap at even faster speeds with our newly expanded VA-3® offerings!


What makes it possible to tap faster is the new VA-3® coolant-through capability. It prevents overheating and improves chip removal rates. As a result, you can achieve faster cutting speeds and smoother chip evacuation! In addition to the coolant-through capability, the new VA-3 taps offer DIN overall length for longer reach applications. The EXOTAP VA-3® series has become even more versatile to address your challenging needs.

 

 

In addition to these new features, the VA-3® taps feature optimized geometry specifically designed for stainless and carbon steels. OSG’s patented V coating provides excellent wear resistance and extended tool life. If cost savings and efficiency are in your To-Improve-List, give OSG’s EXOTAP VA-3® taps a try!

 

 

Spiral Flute      

List 307 - Inch  

List 347 - Metric  

 

Spiral Point

List 306 - Inch 

List 346 - Metric 

 

Faster Production with the WXS® High Feed Corner Radius End Mill

Jacob Van Oost, District Manager


The die and mold industry is a very competitive sector. Shops are constantly 
striving to
 outperform
 competitors by 
quoting shorter 
delivery time, better finish, and lower cost per
 unit. At OSG, we go beyond the quote to demonstrate our abilities in action. With our EXOCARB® WXS® High Feed Corner Radius End Mill, shops are able to achieve faster feed rates, superior surface finishes, and better overall cycle times.

Working with a shop specializing in automotive work in Muskegon, MI, the engineer there wanted a tool that could speed up a process for adding a groove in a P-20 with a 0.25” wide gasket track going around the whole part. The customer originally had it programmed with a 0.25” end mill, but it was taking 3.25 hours to put in the groove. After evaluating the application, we recommended OSG’s EXOCARB® WXS® High Feed Corner Radius End Mill to get the job done.


This corner radius cutter is extremely rigid with a long reach capability. The reverse taper on the cutting edge prevents chattering and eliminates dwell marks on sidewalls. With a new WXS® coating, this end mill oxidizes at around 1300° C, allowing it to withstand much greater heat than competitor tools that are treated with TiAlN.


Initially, we wanted to start the tool at 1,300 RPM and 715 IPM. However, after getting a more detailed look into the program, we realized that the machine for this job could not handle such an aggressive feed rate. To resolve this issue, we decided to cut everything in half, bringing it down to 650 RPM and 357 IPM. Using the EXOCARB® WXS® High Feed Corner Radius End Mill with a light depth of cut, this part of job was completed two hours faster than the original method, and the program time was reduced to merely 35 minutes. The customer was thrilled with the result, and they now use this corner radius end mill to reduce production time overall.


Beyond the automotive industry, this dynamic tool can be applied
 to many applications in die/mold shops. For detailed, 3D contoured parts, it can be used in conjunction with the true 4-flute ball mill. It leaves smaller scallops and has faster metal removal rates than that of ball nosed end mills, making it ideal for roughing. Smaller scallops also makes finishing with the true 4-flute easier and faster, allowing customers to go from roughing straight to finishing, bypassing semi-roughing altogether.


To stay ahead of the competition with faster production, OSG’s EXOCARB® WXS® High Feed Corner Radius End Mill will bypass extra processes along the way.