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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 by Takahiro Yamamoto, OSG Corporation Applications Engineer (Drill Development Division)  Figure 1. ADO-TRS’ unique R gash geometry enables low cutting resistance and creates short and compact chips stably 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’ DrillThere 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. 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. Excellent Chip Formation and Evacuation in Steel Applications Figure 2. Chip shape comparison in 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. Low Resistance Drilling Figure 6. Cutting resistance (thrust resistance) comparison in SCM440. Next, figure 6 illustrates a comparison of cutting resistance when processing under the cutting condition depicted in figure 2.
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.
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 OSG is 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:
The PHOENIX® PDZ indexable flat drill offers the following features & benefits:
 OSG is 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:
Stable and high efficiency in small diameter deep-hole applications. by 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 Figure 1: Chips generated at the tip of the tool flow in the direction of the blue arrow 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.
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 3. Exit room at end of margin Oil HolesThe 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 CoatingAnother 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 DataFigure 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. Enhancing sustainability by tool reconditioning and recycling services by Masatoshi Kageyama | OSG Corporation As a global company manufacturing responsible products, OSG is committed to a healthy planet and society. In order to reduce environmental impact, OSG actively implements initiatives relating to resource and energy conservation, waste reduction, prevention of pollution, and material recycling in various processes throughout the OSG Group. OSG’s tool reconditioning program is a part of the company’s commitment to promote resource conservation and to improve energy efficiency in its business activities.  Figure 1. OSG USA Process of tool reconditioning. The primary benefit of tool reconditioning is obvious: reduction in overall tooling costs. Although many shops regrind their own drills, few shops have given thought to regrinding high performance cutting tools, even though substantial cost savings can be obtained. These efforts not only save customers thousands of dollars each year but are also environmentally friendly and sustainable.  Figure 2. Significant cost reduction can be achieved by tool regrinding alone. As a comprehensive cutting tool manufacturer, OSG is capable of regrinding and recoating an array of products, such as solid carbide tools, HSS tools, PCD tools, rolling dies, specials, and more. Tool reconditioning services provided by OSG restore used tools to like-new condition. OSG’s tool reconditioning division uses original OSG manufacturing drawings for all regrinding processes. OSG Group companies also adhere to the OSG quality control manual and use the same inspection equipment used by the manufacturing division during the inspection procedures. With tool reconditioning facilities in 14 countries, OSG can respond to customer needs worldwide. In addition to tool reconditioning, OSG also offers customization services to help manufacturers optimize machining based on individual application needs.  Figure 3. The condition of a 3-flute drill before and after tool reconditioning. With the capability and expertise to bring worn cutting tools back to life for a fraction of the cost of a new tool, reconditioning is highly economical and environmentally friendly OSG USA's Regrind CapabilitiesOSG USA has comprehensive Regrind and Coating Capabilities for Drills, End Mills, Reamers, Taps and more! Get the best coating based on your application and tool. Additional Coatings available. Drills Figure 4. An example of a tool modification to minimize burrs during drilling.
End Mills
Reamers
How to Get the Ball RollingEvaluation Services Tailored for Your Needs To begin, contact your nearest Next Generation Tool regional manager to set up an evaluation appointment. We will evaluate each and every one of your application before sending the tools off for reconditioning.  Carbide tools that can no longer be reground can be recycled through OSG’s group company Nihon Hard Metal’s carbide recycling program.  OSG has expanded their A Brand AE-N series! The new additions to their advanced performance DLC Coated end mills, are designed for non-ferrous materials in a wide range of cutting applications delivering efficient and quality processing. The following list numbers are associated with the A Brand AE-N End Mill Series expansion: This series offers the following features & benefits:
A Brand AE-VTS-N (8830) Advanced Performance DLC Coated End Mills for Non-Ferrous Materials. The AE-VTS-N high performance DLC coated carbide end mill for non-ferrous materials is suitable for a wide variety of applications with high efficiency and quality. Its DLC-IGUSS coating further improves tool life with excellent welding resistance and lubricity, which is effective in the machining of non-ferrous materials such as aluminum alloys.  OSG is pleased to announce the release of their NEW OSG PHOENIX® PDZ Flat Drill Series!
The OSG PHOENIX® PDZ is an indexable drill series designed for stable flat-bottom hole making. It is an ideal solution for a wide variety of materials such as carbon and alloy steel, stainless steel and cast iron. The following list numbers are associated with the new OSG PHOENIX® PDZ Flat Drill series:
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NEWSOur NEWS blog section is written by several different people. Sometimes, it from our team here at Next Generation Tooling & at other times it's by one of the manufacturer's we represent. 
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