New Tooling Solutions Product Catalog of OSG USA, INC. Provides Comprehensive Solutions for Cutting Tools

 

OSG USA, INC. has introduced its highly anticipated Tooling Solutions Product Catalog in print and in digital versions. The latest catalog edition is over 1,700 pages and includes over sixty new list numbers of its latest and greatest cutting-tool additions.

 

OSG Tooling Solutions Product Catalog Features:

-  60+ NEW List Numbers

-  Refreshed Design

-  Improved PDF Usability – Bookmarks, In-Document Shortcuts, Item Links to Website

-  New QR Codes to Easily Access Product Series Details and Product Videos

-  New Stock Status Columns to Help Easily Identify Product Availability

 

The OSG Tooling Solutions Product Catalog can be accessed digitally here. Customers may also request a free hard copy by contacting OSG Customer Service at 1-800-837-2223 or may order it online here.

OSG Announces the Expansion of the HY-PRO® CARB VGM Series

We are pleased to announce the expansion of our HY-PRO® CARB VGM offering with the addition of the NEW VGM-NIK high-performance variable geometry nicked end mills.

The following list numbers are associated with the HY-PRO® CARB VGM Series Expansion:

 

The HY-PRO® CARB VGM-NIK offers the following features & benefits:

✓ Variable Index - Reduces vibration during machining

✓ Unique Flute Geometry - Maintains excellent cutting-edge sharpness and tool rigidity

✓ EXO Coating – Provides longer tool life through exceptional wear and heat resistance.

✓ Chipbreaker – Creates small manageable chips

OSG Announces the Expansion of the HY-PRO® CARB VGM Series

 

We are pleased to announce the expansion of our HY-PRO® CARB VGM offering with the addition of the NEW VGM3-AL high-performance variable geometry end mills.

The following list numbers are associated with the HY-PRO® CARB VGM Series Expansion:

 

The HY-PRO® CARB VGM3-AL offers the following features & benefits:

✓ Variable Index - Reduces vibration during machining

✓ Unique Flute Geometry - Maintains excellent cutting-edge sharpness and tool rigidity

✓ Center Cutting – 3 cutting edges to center; ideal for plunging and ramping

ADO-MICRO Small Diameter Coolant-Through Carbide Drill

Stable and high efficiency in small diameter deep-hole applications.

- Hiroyuki Amano, OSG Corporation Applications Engineer (Drill Development Division)

 

OSG Corporation has recently released the ADO-MICRO – the company’s first small diameter carbide drill with oil holes designed for stable and high efficiency drilling in deep-hole applications. The sense of size upon hearing the phrase “small diameter” will be understood differently among users in the manufacturing industry.

 

The ADO-MICRO has a lineup of drill diameters from 0.7 mm up to 2 mm for drill lengths of 2xD and 5xD, and diameter 1 mm to 2 mm for drill lengths of 12xD, 20xD and 30xD. The product name ADO-MICRO may seem to be associated with the unit prefix micro (µ), but it was named to simply imply smallness in size regardless of the unit.

 

For small diameter drilling, options such as carbide drills and HSS drills using external coolant are available. However, today’s machining needs require greater stability, higher efficiency and longer life than ever before. There is no exception in small diameter deep-hole applications, with growing needs for coolant-through small diameter drills.

 

Tool Geometry

One of the keys for successful small diameter drilling is trouble-free chip evacuation. As illustrated in figure 1, chips generated at the tip of the tool flow in the direction of the blue arrow. However, if there is insufficient space in the flute, cutting chips cannot evacuate smoothly, which causes the drilling accuracy to deteriorate and increases the probability of tool breakage. Therefore, by providing a wider flute specification at the area where the tip of the blue arrow locates, as depicted in figure 1, cutting chips are able to be discharged without difficulty, leading to stable machining.

 Fig 1. Extended Flute

Figure 1. Extended flute

In addition, the ADO-MICRO employs a unique double margin geometry (as depicted in figure 2) in all sizes to enable stable machining even in deep-hole applications. In order to ensure the rigidity of the cutting edge, the margin is set to the minimum necessary length. However, micro sludges can be easily accumulated around the outer periphery of the cutting tool, which is a key cause of abrupt tool breakage. To resolve this challenge and to achieve an overall balance, an extended flute configuration is incorporated to provide sufficient exit room as shown in figure 3.

Figure 2. Four support points with the double margin design

Figure 2. Four support points with the double margin design

Figure 3. Exit room at end of margin

Figure 3. Exit room at end of margin

 

Oil Holes

The ADO-MICRO features a straight hollow shank design where coolant is injected in addition to the two spiral oil hole paths. This configuration increases coolant discharge from the tool tip. Without the hollow shank configuration, greater pressure is required in order for the coolant to pass through the thin oil hole paths. With the hollow shank feature, pressure loss is reduced, which increases the coolant flow volume. As illustrated in figure 4, with a higher coolant flow rate, cutting chips can be more effectively evacuated, thereby enabling stable machining.

Figure 4. Relationship between shank structure and coolant flow volume

Figure 4. Relationship between shank structure and coolant flow volume

 

OSG’s Latest Coating Technology: IchAda Coating

Another key element for achieving stable processing in small diameter deep-hole application is coating technology. The role of tool coating is to provide wear resistance and heat resistance to prolong tool life, which is particularly important to small diameter tooling. As illustrated in figure 5, the coating surface by conventional technology is not smooth, which may interfere with the performance of chip evacuation. OSG’s latest IchAda coating, on the other hand, provides excellent surface smoothness in conjunction with high wear resistance and heat resistance to enable small diameter tools to achieve long tool life by improving adhesion.

Figure 5. Surface of coating

Figure 5. Surface of coating

 

Cutting Data

Figure 6 demonstrates a comparison of tool life between the ADO-MICRO and two other tooling manufacturers’ products in the machining of SCM440. The competitor drills have chipped or have broken at the initial machining stage. The ADO-MICRO, on the other hand, was able to achieve long tool life stably due to its superior chip evacuation capability by breaking chips into small and manageable pieces.

Figure 6. Stable and long tool life in SCM440

Figure 6. Stable and long tool life in SCM440

The ADO-MICRO demonstrates stable performance even in difficult-to-machine titanium alloy applications. As shown in figure 7, the competitor drill struggled with chip evacuation, thus requiring step processing. However, with the ADO-MICRO, step processing can be eliminated while achieving approximately five times the drilling efficiency. The ADO-MICRO was still in good shape after doubling the competitor drill’s tool life, allowing it to be used on other applications.

Figure 7. Efficiency improvement in titanium alloy

Figure 7. Efficiency improvement in titanium alloy

The ADO-MICRO’s unique tool geometry and OSG’s original IchAda coating allow non-step drilling even for deep-hole applications, enabling high processing efficiency. By eliminating common complication in small diameter deep-hole drilling, the ADO-MICRO is able to excel with stable performance in a wide range of work materials including stainless steel. In addition to standard stock items, OSG also offers customization services with tailored solutions for each and every manufacturer’s specific machining needs.

 

For more information: Click Here

OSG Announces the Expansion of the PHOENIX® PDZ Series

We are pleased to announce the expansion of our PHOENIX® PDZ offering with the addition of the NEW PDZ-3D indexable flat drill.

The following list numbers are associated with the OSG PHOENIX® PDZ Series Expansion:

  • NEW! List #52514         OSG PHOENIX® PDZ-3D (inch)
  • NEW! List #78538         OSG PHOENIX® PDZ-3D (metric)

The PHOENIX® PDZ  indexable flat drill offers the following features & benefits:

✓ Flat bottom cutting-edge configuration is compatible with a wide range of applications - drilling, counterboring, inclined surfaces

✓ Enhanced muscle breaker allows for superior chip breaking capability during drilling, counterboring and turning

✓ High precision finishing on flutes improves rigidity, efficient chip evacuation and reduces cutting force

✓ Available in Inch and Metric sizes

OSG Product Phase Out Announcement

We are announcing the phase out and discontinuation of the following list numbers:

Limited quantities of the above products continue to be available, while supplies last. 

OSG Announces the Expansion of the HY-PRO® CARB VGM Series

We are pleased to announce the expansion of our HY-PRO® CARB VGM end mill series with the addition of the NEW VGM3-AL! The HY-PRO® CARB VGM3-AL is a is a series of Variable Geometry end mills for High Speed Machining in Aluminum and Non-Ferrous Materials.

The following list numbers are associated with the NEW VGM3-AL series:

The HY-PRO® CARB VGM3-AL end mill offers the following features & benefits:

Center Cutting - 3 cutting edges to center; ideal for plunging and ramping.
Variable Index - Reduces vibration during machining.
Unique Flute Geometry - Maintains excellent cutting edge sharpness and tool rigidity

OSG USA, Inc. promotes Andrew Matt to Vice President of Human Resources

 

OSG USA, Inc. promotes Andrew Matt to Vice President of Human Resources

St. Charles, IL- September 1, 2023

 

 

Andrew Matt, the former Director of Human Resources, will be responsible for leading the development and execution of Human Resources strategies for OSG USA, Inc.  

 

“I am very excited to support OSG USA, Inc. in my new role by continuing to evolve the role of human resources within the organization.  I’m committed to ensuring that HR becomes the collaborative partner to support our journey of innovation and excellence.”

 

Andrew started his career at OSG in 2020 as Regional Human Resources Manager, and prior to his career with OSG, Matt was an Executive Director of Human Resources and Organizational Development with BathWraps (RHT, Inc.) and originally began his Human Resources career with United Stationers (Essendant) as their Manager of Performance Improvement and Training in 2000.

 

Andrew earned his Masters in Business Administration from Marquette University in 1994 after earning Bachelor of Science degree in Organizational Management and Marketing from Marquette University.  Andrew is a Senior Certified Professional (SHRM-SCP) since 2020.  He is a longtime Chicago area native growing up in Riverside and residing in Westmont with his wife and three children. 

 

 

OSG USA Innovator & Elite Leader of the Year Recipients

OSG wouldn’t be one of the best places to work without our innovators and leaders that come to work each day and live by our P.R.I.D.E. values!

2022 Innovator of the Year Recipients:

Corporate Support/Services:

 

Bensenville Factory 1st shift: 

 

Bensenville Factory 2nd shift:

 

Operations: 

 

OSG Parma Factory:

 

2022 Elite Leader of the Year Recipients:

Corporate/Operations: 

 

Bensenville Factory:

 

OSG Parma Factory:

 

Sales: 

 

 

 

 

ADO-TRS ‘Triple Revolution’ 3-Flute Carbide Drill

Ultra-machining efficiency and stability in steel applications

- Takahiro Yamamoto, OSG Corporation Applications Engineer (Drill Development Division)

 

 

Three-flute drills are commonly employed in manufacturing. However, they are mostly used in the processing of materials with short cutting chips and low cutting resistance, such as cast iron, ductile cast iron and aluminum alloy. Three-flute drills are sometimes advertised to be suitable for steel materials such as carbon steel, alloy steel and mild steel. However, with a smaller chip room geometry than 2-flute drills, the cutting thrust resistance in 3-flute drills is also greater.

 

Due to constraints in workpiece configuration, equipment and setup, conventional 3-flute drills often are unable to maximize both speed and precision as advertised. Moreover, in steel processing, the strength of the work material and viscosity are high, making chip separation and stable processing a challenge. With high thrust force and poor chip evacuation, sudden machining troubles such as tool breakage and chipping are common headaches of 3-flute drills.

 

To help manufacturers maximize productivity, OSG has recently introduced a new revolutionary drilling innovation – the ADO-TRS – nicknamed as the ‘Triple Revolution’ drill, for ultra-machining efficiency and stability in steel materials.

 

Features of ADO-TRS ‘Triple Revolution’ Drill

There are three major features that enable the ADO-TRS to stably process steel applications.

  

The most notable key feature is the newly engineered R gash geometry (pat. P) as illustrated in figure 1.

Figure 1. ADO-TRS’ unique R gash geometry enables low cutting resistance and creates short and compact chips stably.

The optimized R shape geometry is designed to control chip flow direction to facilitate trouble-tree chip-evacuation. With this new feature, the ADO-TRS is able to significantly improve chip separation even in steel materials by breaking them into small pieces and consistent shape. In addition, this new geometry can reduce cutting resistance (thrust resistance), by as much as 30 percent versus conventional tooling, enabling it to outperform even 2-flute drills in high-feed processing with minimal cutting resistance.

 

The second key feature of the ADO-TRS is its wide chip pocket configuration.

In 3-flute drills, chips are difficult to be discharged from the center of the drill. The ADO-TRS employs a wide chip room flute geometry to improve chip ejection. Combined with the R gash specification, chips are curled for greater separation capability, which leads to smooth and stable chip evacuation.

 

Last but not least, the ADO-TRS is coated with OSG’s original EgiAs coating for high durability. The EgiAs coating is consist of overlapping nano-periodical layers and wear-resistance layers, engineered to suppress the propagation of cracks that are likely to occur during drilling. The wear-resistance layer is composed of multiple hard layers; while the nano-periodical is a combination of hard and soft layers. With a mixture of hard and soft layers, internal stress can be relieved, allowing the EgiAs coating to achieve both high wear resistance and extreme toughness to ensure stable and consistent tool life under aggressive cutting conditions.

 

Cutting Data

1. Excellent Chip Formation and Evacuation in Steel Applications

Two of ADO-TRS’ most notable benefits are its superior chip management and low resistance drilling capability in steel materials.

 

SCM440 (raw) is one of the more viscous materials among steels. When processing this material with MQL, chips generated by conventional 3-flute drills and 2-flute drills are elongated as depicted in figure 2. As depicted in figure 3, the conventional 3-flute drill is unable to break chips into small pieces. As a result, remnants of elongated chips remain in the flute of the drill. The ADO-TRS, on the other hand, is able to demonstrate excellent chip form consistently as shown in figure 2.

Figure 2. Chip shape comparison in SCM440.

 

Figure 3. Condition of the conventional 3-flute drill after processing SCM440.

 

 

Figure 4. Chip shape comparison in SS400

 

Figure 5. Tool life comparison in SS400

 

Moreover, in the processing of SS400 using water-soluble coolant, sudden tool damage and chipping caused by tangled chips are prone to occur. The stability in chip formation and evacuation is a key factor for achieving stable processing in mild steel SS400, which is particularly prone to chip problems. As illustrated in figure 4 and figure 5, the ADO-TRS demonstrates overwhelming chip separation capability and long tool life even in the processing of SS400 in comparison to the conventional 3-flute drill and 2-flute drill.

 

2. Low Resistance Drilling

Next, figure 6 illustrates a comparison of cutting resistance when processing under the cutting condition depicted in figure 2.

Figure 6. Cutting resistance (thrust resistance) comparison in SCM440.

 

As shown in figure 6, the ADO-TRS is able to reduce thrust resistance by approximately 35 percent versus conventional 3-flute drills, and generated even less overall thrust resistance when compared to a standard 2-flute carbide drill, which has one less flute and larger chip rooms. Under identical cutting condition, the ADO-TRS is able to achieve the lowest thrust resistance.

 

Due to high cutting resistance inherent in conventional 3-flute drills and the various constraints present in processing environment, such as the machine, workpiece geometry, work fixture, etc., conventional 3-flute drills are often unable to maximize high-feed performance and precision. The ADO-TRS, on the other hand, excels in wide range of cutting conditions, truly reflecting its versatile capability.

 

Next, we will evaluate the performance of the above features combined with OSG’s original EgiAs coating in the following case study, where the ADO-TRS is able to demonstrate long tool life and stable processing in a crankshaft made of alloy steel. In terms of shape, although the work holding force (clamp) at the time of processing is not high, the effect of the low cutting resistance of the ADO-TRS is able to surpass the carbide 2-flute drill with greater feed-rate. As shown in figure 7, the ADO-TRS is able to achieve higher efficiency and significantly reduce processing time versus the competitor 2-flute drill.

 

Figure 7. Case study of machining time and tool life improvement in the processing of an automotive crankshaft.

 

As depicted in this case study, the ADO-TRS is able to demonstrate exceptional stability, high-productivity, long tool life in steel materials, which conventional tools are challenged by instability. Furthermore, with capabilities to resolve common challenges of 3-flute drills such as high thrust force and poor chip evacuation in steel applications, the ADO-TRS is setting a new standard for 3-flute drills with reliable performance never witnessed before in the cutting tool sector.

 

The ADO-TRS’ unique R gash geometry feature has also been applied to OSG’s ADO 40xD and 50xD carbide drills with through coolant for highly efficient deep-hole drilling. The R gash geometry enables super low cutting resistance and exceptional chip control, optimized for superior performance in ultra-deep-hole applications. This geometry has proven success not only in 3-flute drills, but also in 2-flute drills. OSG will look to apply its superior tooling geometry to other products to further enhance productivity, tool life, stability and precision.

 

For manufacturers who are especially struggling with chip evacuation problems in steel applications, look to the ADO-TRS to experience ultra-machining efficiency and stability.

 

The ADO-TRS is available from diameter 3 mm up to 20 mm, in processing depth of 3xD and 5xD, and is suitable for applications in carbon steels, alloy steels, mild steels, cast iron and hardened steels.

 

Photo Captions

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

ADO-40xD 50xD. The ADO-TRS’ unique R gash geometry feature has also been applied to OSG’s ADO 40xD and 50xD carbide drills with through coolant for highly efficient deep-hole drilling. The R gash geometry enables super low cutting resistance and exceptional chip control, optimized for superior performance in ultra-deep-hole applications.