A-SIGMA-SFT spiral fluted tap and SynchroMaster tap holder accelerate productivity with reliable performance in carbon steel hub production
Lucas Sousa do Nascimento | OSG Sulamericana
Founded in 2018, Imagem Automação e Usinagem Ltda. (Imagem Automação) is a manufacturer of machinery parts, servicing markets such as aeronautics, defense, medical, machinery and equipment, among others. Employing 40 staff, Imagem Automação’s facility is located in the city of São José dos Campos, São Paulo, Brazil, with an estimate production area of 2,000-square-meter. Imagem Automação is equipped with several 5-axis, 4-axis and 3-axis machining centers, CNC lathes, milling machines, cylindrical and flat grinders, as well as advanced inspection instruments to ensure quality and accuracy in its production.
Imagem Automação is equipped with several 5-axis, 4-axis and 3-axis machining centers, CNC lathes, milling machines, cylindrical and flat grinders, as well as advanced inspection instruments to ensure quality and accuracy in its production.
Recently, Imagem Automação was looking to improve the tool performance on its hub production for a manufacturer of high precision and performance machines and equipment. The parts are made of SAE 1045 (JIS S45C) carbon steel and has an annual production volume of 120 pieces. Fifteen 3/8-16 UNC-2B blind holes at a depth of 18 mm are required to be threaded per part. The threads on the part are aligned in several positions. All of the threading processes were initially performed manually using hand taps introduced by a distributor. A hand tap set consists of three taps – taper tap, plug tap and bottoming tap. The taper tap is used as a starter tap, followed by the plug tap, and the blind hole is completed by the bottoming tap. Occasionally, a tapping arm was used for the first tap. However, for much of the time, all three processes were performed by hand. Long cycle time of 225 minutes was needed to process one part with 15 threads, which included setup time and tool change. Seeking to enhance productivity, Imagem Automação reached out to OSG Sulamericana via a professional network service provider.
All of the threading processes were initially performed manually using hand taps introduced by a distributor. Long cycle time of 225 minutes was needed to process one part with 15 threads, which included setup time and tool change.
Shortly after, OSG Sulamericana Regional Sales Leader Edson Veras and OSG Sulamericana Technical Sales Representative Allan Siqueira visited Imagem Automação to investigate the machining environment. Upon a detail evaluation of the application, the duo recommended switching from manual processing to leveraging the company’s existing Mikron MILL E700U 5-axis machining center. In terms of tooling, instead of hand taps, OSG recommended the A-SIGMA-SFT spiral fluted tap (EDP# 49264124 – DIN 2183 3/8-16 UNC TiN) from the A-Tap Σ (sigma) series along with the SynchroMaster tap holder (EDP# 79913 – HSK63A-SMH-16-90), which is designed to turbocharge tapping performance on CNC machines with synchronous spindles by compensating for synchronization errors during the threading process.
Right, OSG Sulamericana Technical Sales Representative Allan Siqueira explains the features of the A-Tap Σ (sigma) spiral fluted tap and the SynchroMaster tap holder.
The A-Tap Σ (sigma) is a part of OSG’s well-known A-Tap multi-purpose tap series. Developed in line with the core concept of the A-Tap series with superior chip evacuation capability, the A-Tap Σ is the new excellence for cost-effective threading applications. The A-Tap Σ (sigma) series includes the A-SIGMA-SFT spiral fluted tap for blind holes and the A-SIGMA-POT spiral pointed tap for through holes. The A-Tap Σ features a sharp cutting edge to stabilize chip shape and a variable lead flute geometry to accelerate chip evacuation. Made of HSS-E (JIS SKH53 equivalent) and coated with TiN, the A-Tap Σ is designed to excel in a wide range of work materials and cutting conditions with excellent durability and wear resistance. The A-Tap Σ not only excels in mid and high carbon steel and alloy steels, but is also suitable for mild steel, stainless steel and aluminum alloy – materials that conventional general taps often struggle with.
To help manufacturers who use machining centers with synchronous spindles overcome common tapping obstacles such as sudden tool breakage, unstable tool life and poor thread quality, OSG Corporation has introduced a new generation synchronized tap holder – the SynchroMaster – engineered to turbocharge performance by dampening excessive forces in rigid tapping environment.
The SynchroMaster is a tap holder constructed to allow a slight amount of axial movement to compensate for axial deviations that are unavoidable in rigid tapping. Its micro tension-compression float eliminates the extra axial forces on the tap, leading to longer tool life, consistent tapping depth and improved thread quality. The SynchroMaster tap holder is especially recommended to manufacturers who are struggling with unstable tool life, poor thread quality, low productivity and large variations in depth length on rigid tapped holes.
The 3/8-16 UNC A-SIGMA-SFT spiral fluted tap is used at a cutting speed of 20m/min and 668 rpm with soluble oil coolant (8%). With the new machining arrangement and tooling combination, cycle time has been reduced from 225 minutes to 1 minute per part (15 threads), including time required for setup and positioning.
The A-Tap Σ (sigma) series includes the A-SIGMA-SFT spiral fluted tap for blind holes and the A-SIGMA-POT spiral pointed tap for through holes. The A-Tap Σ features a sharp cutting edge to stabilize chip shape and a variable lead flute geometry to accelerate chip evacuation. Made of HSS-E (JIS SKH53 equivalent) and coated with TiN, the A-Tap Σ is designed to excel in a wide range of work materials and cutting conditions with excellent durability and wear resistance.
In addition to the dramatic reduction in cycle time, Imagem Automação estimated that overall manufacturing time is reduced by 32 percent per part. Moreover, tool breakage has been minimized while thread quality has improved.
From left, OSG Sulamericana Regional Sales Leader Edson Veras, Imagem Automação Executive Director Paulo Krug, Imagem Automação CNC Programmer Igor Limeira, Imagem Automação Production Manager Leonardo Rocha, and OSG Sulamericana Technical Sales Representative Allan Siqueira pose for a photograph at Imagem Automação’s manufacturing facility in São José dos Campos, São Paulo, Brazil.
Imagem Automação is committed to the continuous improvement of production processes, products and services. By leveraging OSG’s A-SIGMA-SFT spiral fluted tap and SynchroMaster tap holder, Imagem Automação is able to accelerate productivity with reliable performance in its hub production to guarantee the satisfaction of its clients.
For more information on Imagem Automação, OSG Sulamericana and the A-Tap Sigma series (Portuguese only)
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