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AE-VMS Carbide End Mill Boosts Productivity and Reliability in Stainless Steel Pistol Slide Production

Sal Pinnola | OSG USA

Founded in 2011, Azimuth Technology is a precision manufacturer of firearms related components, explosives detection equipment, and other products and components for discerning customers throughout the world in sectors such as defense, aerospace, and oil and gas.

Azimuth Technology is a contract manufacturer dedicated to large run manufacturing of original equipment manufacturers (OEMs) and large volume partners. Some of the company’s key products include drop-in barrels, pistol slides and bolt carrier groups. Azimuth Technology also produces major OEM component parts for well-known, trusted firearms brands in the United States and worldwide.

Employing 240 staff, Azimuth Technology is headquartered in the city of Naples, Florida, United States, with an estimate production space of 9,298-square-meter and houses some of the most advanced equipment and machining tools available. This includes over 260 modern CNC machine tools.  Its manufacturing plant is ISO 9001:2015 certified and maintains the highest quality control standards to deliver exceptional manufacturing quality for industries where precision operation is critical.

A photograph inside Azimuth Technology’s production facility in Naples, Florida, USA. Photo Courtesy of Azimuth Technology.

Recently, Azimuth Technology was looking to improve tool performance on its pistol slide production, which the company has been manufacturing for the past five years. The slide is used as one of the main mechanisms on a pistol that encases the barrel inside and slides back and forth on the firearm as it is being fired to help eject and load the next round into the barrel. The part is made of 17-4 stainless steel and has an annual production volume of over 100,000 pieces.

The part requires a feature that is produced by slotting with a 4 mm end mill to leave room for cleanup with a finishing end mill. The pocket on the part is 0.27-inch deep, 0.5-inch long and 0.18-inch wide. Each part has one pocket and requires parallel walls with a +/- 0.001-inch tolerance on the right angle when finished. The parts are processed using an Okuma Genos 460-VE 40 taper vertical CNC machining center and the tools are held by a hydraulic milling chuck.

Azimuth Technology was originally using a competitor 4 mm diameter 3-flute end mill with coolant through the shank. They have been using a hydraulic tool holder to reduce runout on the tool and increase clamping pressures on the tool shank. However, Azimuth Technology had been experiencing inconsistent tool wear, which in turn affected the consistency of the company’s tooling expenses as it would vary month-to-month. Moreover, the inconsistency also made Azimuth Technology unable to predict tool change, which often resulted in tool breakage and unwanted machine downtime.

Azimuth Technology has known OSG for many years and has been using OSG products, but they were mainly taps and drills. The idea of OSG having a great high performance end mill was not something they had thought of before. Sal Pinnola, OSG USA’s Florida Territory Sales Manager was presented with an opportunity to conduct a test trial because Azimuth Technology was struggling with tool life consistency and the price per tool.

Upon a detail evaluation of the application, Pinnola recommended a 4 mm diameter 4-flute AE-VMS square carbide end mill with 11 mm length of cut (EDP# 8555840) from the AE-VM series. The AE-VMS short carbide end mill is a part of OSG’s AE-VM anti-vibration carbide end mill offering, a series designed to attain a new level of milling efficiency coupled with superb finish quality suitable for a variety of milling applications.

AE-VMS short carbide end mill from OSG’s AE-VM anti-vibration carbide end mill series.

The short type AE-VMS enables stable machining with a unique flute form that achieves both tool rigidity and trouble-free chip evacuation, and also suppresses burrs, which is a common obstacle in part processing. With the addition of OSG’s original DUARISE coating, tool life can be enhanced by its excellent lubricity, superior friction-resistance and high oxidation temperature qualities. Available in various styles and configurations, the AE-VM series is designed to accommodate a wide range of milling operations including slotting, side milling, helical milling, contour milling and ramping in stainless steel, cast iron, carbon steel, alloy steel and hardened steel.

Azimuth Technology’s vertical machining center uses a water-soluble coolant and they are able to run the AE-VMS without any coolant through the spindle. During the cutting trial, Azimuth Technology ran the OSG AE-VMS end mill at a cutting speed of 200 sfm (61 m/min), a spindle speed of 4,850 rpm, a feed per tooth of 0.0013-inch (0.033 mm/t), a table feed of 25.22 inch/min (640 mm/min), and an axial depth of cut of 0.09 inch per pass performing a slotting function with a metal removal rate of 0.357 inch3/min. The competitor tool was used at a cutting speed of 350 sfm (107 m/min), a spindle speed of 8,520 rpm, a feed per tooth 0.001-inch (0.0254 mm/t), a table feed of 25.56 inch/min (649 mm/min), and an axial depth of cut of 0.06 inch (1.524mm) per pass with a metal removal rate of 0.242 inch3/min.

A 4 mm diameter 4-flute AE-VMS square carbide end mill with 11 mm length of cut (EDP# 8555840) from OSG’s AE-VM series.

The tool life of the competitor 3-flute end mill averaged around 50 cycles at five parts per cycle, which is equivalent to 250 parts. The AE-VMS carbide end mill, on the other hand, is able to complete 350 parts before wearing out. By switching to OSG’s AE-VMS end mill, Azimuth Technology is able to increase tool life by 40 percent, with approximately 20 more cycles and 100 more parts. The improvement facilitated more machine uptime, shortened cycle time, and also reduced the cost per tool by over 50 percent in this application, leading to a cost savings of over $18,000 USD per year. Additionally, the increased metal removal rate contributed to a boost in the number of parts produced per hour, resulting in Azimuth Technology’s customer being able to receive parts sooner.

From left, Azimuth Technology Tooling Manager Ben Guynn and Azimuth Technology Programmer Alex Kolb pose for photograph inside the company’s production facility in Naples, Florida, USA.

“The AE-VMS is half the price versus the previous tool, and it works that much better,” said Azimuth Technology Programmer Alex Kolb. “Why wouldn’t we switch to OSG?”

For more information on OSG’s AE-VM anti-vibration carbide end mill series and Azimuth Technology

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.

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:

•        NEW!  List #VGM5-NIK HY-PRO^® CARB VGM5-NIK
•        NEW!  List #VGM7-NIK HY-PRO^® CARB VGM7-NIK

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

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:

•        NEW!  List #VGM3-AL HY-PRO^® CARB VGM3-AL

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

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.

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 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

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

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

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

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

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

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. 

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:

• NEW! List #VGM3-AL   

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

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.