ADO-MICRO coolant-through carbide drill and ADF flat drill enhance productivity and tool life in small part production
The machining of small components is not new in the manufacturing industry, but the trend for lighter weight and further miniaturization continues to accelerate. Industries such as automotive, aerospace, electronics and medical require the machining of an array of small parts.
In general, any workpiece that is less than 25.4 mm in diameter can be considered as small. Application with a part diameter less than 0.5 mm can be classified as micromachining. With reduced weight and material, holes required to be drilled have also become smaller. Tool breakage is a common concern in small part production, as the slightest variation can cause a tool to snap. Due to tight tolerances, cutting tools used in the machining of miniature components require sharpness, high surface quality, accuracy and performance stability.
With advanced grinding know-how, OSG offers a spectrum of tooling solutions to fulfill increasing needs of small and micromachining. OSG’s small diameter and micro tooling incorporate high precision shank, optimum tool geometry, grade, and a wide variety of coating options to enable stable and accurate machining of small and micro parts.
Recently, a leading manufacturer of precision parts in Thailand was able to leverage some of OSG’s latest drilling innovations in the production of high-pressure pump part and automotive part to eliminate tool breakage and stabilize machining.
Global-Thaixon’s manufacturing plants are located in Chachoengsao, Thailand, with an estimate production floor space of 32,700-square-meter.
Found in 1990, Global-Thaixon Precision Industry Co., Ltd. (Global-Thaixon) is a leading manufacturer of precision components for a wide variety of industries worldwide, serving sectors such as automotive, electronics, medical, and more. Employing 900 staff, Global-Thaixon’s manufacturing plants are located in Chachoengsao, Thailand, with an estimate production floor space of 32,700-square-meter.
Global-Thaixon offers a complete range of machining and turning capabilities, including close to 400 sets of CNC machines operating around the clock.
Global-Thaixon offers a complete range of machining and turning capabilities, including close to 400 sets of CNC machines operating around the clock. The company’s tooling and milling department are equipped with advanced computerized production control system, which enables high precision and efficient production of complex parts. Aside from turning and milling, Global-Thaixon also has a variety of stamping machines ranging from 25 tons to 160 tons for making high precision progressive mold for metal stamping parts with short lead time.
Recently, Global-Thaixon was experiencing tool breakage and short tool life in its spool and valve seat applications. Seeking to improve productivity, tooling cost and profits, Global-Thaixon reached out to OSG for technical support.
Spool Application
Spool – a high-pressure pump part made of SCM415. Each part requires the drilling of one blind hole at a depth of 36 mm.
Spool is a high-pressure pump part made of SCM415. This part is currently at the prototype stage and the production volume varies. One blind hole at a depth of 36 mm is required to be drilled per part. The accuracy of hole diameter needs to be within +/- 0.05 mm. The parts are machined using CNC lathes. Global-Thaixon was originally using a competitor drill for the machining. However, the holes were not straight, had poor hole roundness and concentricity. Upon a detail evaluation of the application, OSG Thai Sales Representative Tantip Luangthongsri recommended OSG’s ADO-MICRO.
OSG’s ADO-MICRO small diameter coolant-through carbide drill is used in the processing of Global-Thaixon’s high-pressure pump part made of SCM415.
The ADO-MICRO is OSG’s first small diameter carbide drill with oil holes designed for stable and high efficiency drilling in deep-hole applications. Poor chip evacuation is a common complication in small diameter deep-hole drilling. Micro sludges can be easily accumulated around the outer periphery of the cutting tool, which is a key cause of abrupt tool breakage. The ADO-MICRO features a unique double margin geometry with an extended flute and shortened end margin to enhance chip evacuation capability. In addition to the outstanding chip ejection performance, the double margin configuration supports the straightness stability of the tool and reduces rifle marks on the inner surface of holes. Furthermore, the ADO-MICRO features a pair of large oil holes and employs a hollow shank design to allow large coolant flow volume for trouble-free chip evacuation. The ADO-MICRO is coated with OSG’s original IchAda coating that provides excellent surface smoothness in conjunction with high abrasion resistance and heat resistance to enable small diameter tools to achieve long tool life. With the ADO-MICRO’s unique tool geometry and IchAda coating, non-step drilling is made possible even for deep-hole applications, enabling high processing efficiency.
A 2 mm diameter ADO-MICRO-2D (EDP# 8732017) is first used as a pilot drill, followed by a 2 mm diameter ADO-MICRO-20D (EDP# 8732056) to complete the hole. The ADO-MICRO 20 x D is used under identical cutting condition as the initial competitor drill, at a cutting speed of 4,500 rpm and a feed rate of 0.075 mm/rev. Global-Thaixon’s in-house Thaixon Pump is also used to enhance chip evacuation. With the previous tooling choice, 2-step processing was required. By switching to the ADO-MICRO, non-step drilling is made possible and an estimate of 4 seconds of machining time has been shortened per workpiece.
Valve Seat Application
Valve Seat – a small precision automotive part made of EXEO-CR20 (high-strength and corrosion-resistant stainless steel). Six blind holes at a depth of 0.4 mm are required to be processed per part using a 0.32 mm diameter flat drill.
Valve seat is a small precision automotive part made of EXEO-CR20 (high-strength and corrosion-resistant stainless steel). Global-Thaixon has been manufacturing this part for about eight years and has an annual production of approximately 160,800 pieces. Six blind holes at a depth of 0.4 mm are required to be processed per part using a 0.32 mm diameter flat drill. The accuracy of hole diameter needs to be within +/- 0.015 mm. The parts are machined using CNC lathes. Global-Thaixon was originally using a competitor tool and experienced inconsistent tool life and poor hole position accuracy.
OSG’s ADF carbide flat drill enables stable machining of valve seat – a small precision automotive part made of EXEO-CR20 (high-strength and corrosion-resistant stainless steel).
After reviewing the cutting conditions, OSG Thai Sales Representative Tantip Luangthongsri recommended OSG’s ADF carbide flat drill with a customized 0.32 mm diameter. The ADF was developed with an “all-purpose” concept for superior versatility, reliability and quality for flat-bottom holes. Machining a flat hole traditionally required the use of an end mill and a drill. For the processing of thin plate shaft parts, the ADF enables one-step drilling, thereby simplifying machining time and tool management. The drill’s balanced point form improves precision and minimizes the shifting of the hole position. Its sharp cutting edge results in low cutting force to minimize burrs even in thin plates. With a wide chip room geometry, trouble-free chip evacuation can be achieved. Furthermore, with the addition of OSG’s proprietary EgiAs coating, tool life can be prolonged with excellent heat and wear resistance. The ADF series is engineered for a wide variety of drilling applications including inclined surfaces, curved surfaces, counterboring, eccentric holes, thin plates, etc. It is suitable for materials such as carbon steel, alloy steel, hardened steel, cast iron and stainless steel.
OSG’s ADF carbide flat drill and a valve seat.
Global-Thaixon’s initial competitor tool was used at a cutting speed of 20,000 rpm and a feed rate of 0.0050 mm/rev. Performance was unstable, generally averaging between 250 to 600 parts per tool. OSG’s 0.32 mm diameter ADF-2D was tested under identical cutting condition at a speed of 20,000 rpm and a feed of 0.0050 mm/rev. With the initial competitor tooling, the machining accuracy was not stable. Tool life also varied among the supplied lot, making tool management a great challenge. The ADF-2D, on the other hand, enables highly stable machining. Tool life averages around 1,500 pieces, which is more than double the previous tooling choice.
Global-Thaixon Production Engineer Saranphat Liangsakun inspects a part.
“After switching to OSG’s ADO-MICRO and ADF drills, we are able to reduce downtime required for changing cutting tools, increase tool life for reduced tooling cost, and encounter less interruptions in machining due to significant improvement in part quality and accuracy,” said Global-Thaixon Production Engineer Saranphat Liangsakun.
Global-Thaixon has close to 400 automatic lathes (sliding head lathes) and is actively testing newly developed products with a focus on small diameter tools recently proposed by OSG. By leveraging the latest cutting tool technology, manufacturing processes and product quality are enhanced, which ultimately delivers greater values to clients.
From left, Global-Thaixon Production Engineer Saranphat Liangsakun, Global-Thaixon Engineering Director Kazushige Ishizawa and OSG Thai Sales Representative Tantip Luangthongsri pose for a photography at Global-Thaixon’s facility in Chachoengsao, Thailand.
“As a company committed to quality and customer satisfaction, we look forward to the continued partnership with OSG,” said Global-Thaixon Engineering Director Kazushige Ishizawa.
For more information on OSG’s ADO-MICRO small diameter coolant-through carbide drill series and the ADF carbide flat drill series
About Global-Thaixon
Found in 1990, Global-Thaixon Precision Industry Co., Ltd. (Global-Thaixon) is a leading manufacturer of precision components for a wide variety of industries worldwide, serving sectors such as automotive, electronics, medical, and more. Employing 900 staff, Global-Thaixon’s manufacturing plants are located in Chachoengsao, Thailand, with an estimate production floor space of 32,700-square-meter.
Global-Thaixon offers a complete range of machining and turning capabilities, including close to 400 sets of CNC machines operating around the clock. The company’s tooling and milling department are equipped with advanced computerized production control system, which enables high precision and efficient production of complex parts. Aside from turning and milling, Global-Thaixon also has a variety of stamping machines ranging from 25 tons to 160 tons for making high precision progressive mold for metal stamping parts with short lead time.
In addition to the production of precision components, Global-Thaixon also offers high performance pump solution with its original Thaixon Pump, which increases the pressure of cutting oil to improve cutting chip evacuation, thus prolonging the tool life of cutting tools.
Global-Thaixon offers high performance pump solution with its original Thaixon Pump.
For more information on Global-Thaixon
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