Longer Tool Life with Shorter Run Time

A-Tap A-OIL-SFT boosts productivity in axle production

Marcela Rattin Bombini  |  OSG Sulamericana

Founded in 1960, Indústria Mecânica São Carlos (IMSC) is a leading solution provider for the machining and assembly of parts for the automotive and heavy industries in markets of Brazil and abroad. Some of its key products include transmission housings machined in aluminum and cast iron; axles machined in cast iron and rolled or forged steel with or without heat treatment; and assembly of wheel reduction assemblies and brake pads.

Founded in 1960, Indústria Mecânica São Carlos (IMSC) is a leading solution provider for the machining and assembly of parts for the automotive and heavy industries in markets of Brazil and abroad.

Employing 188 staff, IMSC’s manufacturing plant is located in the city of Elias Fausto, São Paulo, Brazil, with an estimate land area of 400,000-square-meterand an industrial warehouse of 12,000-square-meter. 

Some of IMSC’s key products include transmission housings machined in aluminum and cast iron; axles machined in cast iron and rolled or forged steel with or without heat treatment; and assembly of wheel reduction assemblies and brake pads.

Recently, IMSC was looking to improve tool performance on its axle production made for dump trucks, which the company has been manufacturing for about 10 years. IMSC’s goal was to increase the number of fabricated parts per tool while decreasing machine time. The axles are made of steel 39MnCrB6 (350 HB) and has an annual estimate production volume of 78,000 pieces. Two blind holes at a depth of 54 mm are required to be threaded per workpiece with a tap tolerance of 6HX. The parts are machined using an Okuma MA600HB horizontal machining center and a DMG Mori NH 600 horizontal machining center.

IMSC was searching for tap processing improvement in their axle production made of 39MnCrB6 (350 HB). Two blind holes at a depth of 54 mm are required to be threaded per workpiece with a tap tolerance of 6HX.

During a visit to IMSC’s facility, OSG Sulamericana Applications Technician Gabriel Fernando Gialorenço requested a tool trial opportunity to tackle the challenge of production improvement. Upon a detail evaluation of the application, Gialorenço recommended the A-OIL-SFT M22 x 1.5 DIN 374 (EDP# 48139240) from the A-Tap series. 

IMSC Process Engineer Wilson Santos prepares for the machining of the axle part.

OSG’s A-Tap is an all-purpose tap series designed to simplify tool management and to excel in a wide variety of materials and applications. Achieving trouble-free chip evacuation with a spiral tap in blind holes is particularly challenging and is a main cause of headaches for many manufacturers. To resolve this problem and to improve the ejection of chips, OSG’s A-Tap A-SFT has adopted a variable helix flute design, which encourages stable chip evacuation and reduces cutting forces. The helix angle changes from the chamfer, where chips are formed, to the flutes, where chips are evacuated. This unique geometry enables greater chip control that can help produce tightly compacted chips for easy ejection from the hole.

The A-OIL-SFT is able to increase tool life by 20 percent and reduce 4 seconds of machining time per workpiece. With an annual production volume of 78,000 pieces, this time saving is equivalent to a total of 312,000 seconds, or 5,200 hours.

To accommodate a wide range of cutting conditions, powdered metal HSS and OSG’s patented V coating have been employed in this series to achieve excellent wear resistance. In addition, to enable high speed machining, the A-Tap series incorporates a unique cutting-edge design that emphasizes sharpness. Not only does the A-Tap series perform well in general steel, it also excels in difficult-to-machine materials such as stainless steel and mild steel. The A-Tap is compatible with various types of machining equipment – from manual machines to the latest advanced machining centers.

IMSC Process Engineer Wilson Santos prepares for the machining of the axle part.

Due to confidentiality reasons, IMSC’s previous tooling choice cannot be disclosed. However, at the end of the trial, it was revealed that the A-OIL-SFT is used at a cutting speed of 11 m/min versus the previous tool’s 8 m/min. The OSG tool outperforms the competitor tool in both time and tool life. The A-OIL-SFT is able to increase tool life by 20 percent and reduce 4 seconds of machining time per workpiece. With an annual production volume of 78,000 pieces, this time saving is equivalent to a total of 312,000 seconds, or 5,200 hours.

From left to right, IMSC President Lino Fracasso, IMSC Purchasing Analyst Juliana Santana, IMSC Process Engineer Wilson Santos and OSG Sulamericana Applications Technician Gabriel Fernando Gialorenço pose for a photograph at the IMSC plant in Elias Fausto, São Paulo, Brazil.

Any machinist would agree that breaking a tap in a part as one of the final machining operations can be very costly, with significant impact made to the overall production and delivery. By implementing OSG’s A-OIL-SFT, IMSC is able to achieve stable tapping performance and reduce cost in their axle production to deliver high quality products at competitive pricing to their clients.

For more information on OSG’s A-Tap multi-purpose and high-efficient tap series and Indústria Mecânica São Carlos