Custom OIL-C-XPF carbide thread forming tap enhances processing efficiency and reduces cost per unit in connecting rod production
Shan Liang Zhang | OSG Shanghai
A manufacturer of automotive internal combustion engine components located in northern China, whose name cannot be disclosed due to confidentiality reasons, recently consulted with OSG Shanghai regarding their connecting rod production made of C-70 high carbon steel. This manufacturer employs over 3,000 staff in its 300,000-square-meter production facility. The client has been producing connecting rods for approximately five years, with an estimate annual production volume of more than 1 million pieces. This manufacturer was originally using a competitor high speed steel thread tap for the application. However, after a long period of use, the client wanted to investigate alternative options with capabilities to further improve manufacturing efficiency and reduce production costs.
The manufacturer in northern China has been producing connecting rods for approximately five years, with an estimate annual production volume of more than 1 million pieces.
The manufacturer got in touch with OSG through a distributor, and engineers were dispatched to evaluate the application. Two holes are required to be processed on each connecting rod, with one being a through-hole and the other being a blind hole. The hole depth for both holes are 30 mm and the internal thread accuracy requirement is 5H6H. The client is using a BT40 machining center with internal cooling function. The internal cooling pressure is 1.5 MPa, and the client is using a water-soluble coolant with a concentration of about 10 percent for process cooling.
The hole depth for both holes are 30 mm and the internal thread accuracy requirement is 5H6H.
Based on the machining environment and customer requirement, OSG recommended a custom OIL-C-XPF carbide thread forming tap with oil holes. In comparison to high speed steel, carbide has better rigidity and higher heat resistance, which allows greater rotational speed. OSG’s XPF represents a new evolution in forming tap technology. This series is engineered to generate up to 50 percent less torque versus other forming taps, making it feasible to tap materials up to 35 HRC and sizes up to M45 in diameter. Its low-torque design allows for longer tool life at faster speeds. The XPF is available with or without coolant holes, and in standard or long shank style. In addition to JIS standard, OSG Shanghai also offers DIN standard taps. In 2020, the OIL-C-XPF has been newly added to OSG Shanghai’s DIN tap series to provide manufacturers with more powerful tooling to meet specific application needs.
Two holes are required to be processed on each connecting rod, with one being a through-hole and the other being a blind hole.
The OIL-C-XPF is originally coated with OSG’s V coating. However, in order to further maximize performance, the custom OIL-C-XPF is coated with OSG’s proprietary EgiAs coating, which can effectively improve wear resistance, heat resistance, and optimize toughness to ensure stable and consistent tool life under aggressive cutting conditions.
OSG’s XPF represents a new evolution in forming tap technology. This series is engineered to generate up to 50 percent less torque versus other forming taps, making it feasible to tap materials up to 35 HRC and sizes up to M45 in diameter. In 2020, the OIL-C-XPF has been newly added to OSG Shanghai’s DIN tap series to provide manufacturers with more powerful tooling to meet specific application needs.
At the end of the tool trial, the OIL-C-XPF’s performance far surpassed the client’s expectation. Under identical cutting condition, the OIL-C-XPF is able to boost speed to 580 revolutions per minute. In comparison to the previous high speed steel tap, the processing efficiency is increased by 60 percent. By implementing OSG’s OIL-C-XPF, this manufacturer is able to achieve greater productivity and reduce cost per unit in their connecting rod production.
For more information on the OIL-C-XPF and OSG Shanghai
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