ADO-SUS carbide drill and Z-SFT spiral flute tap demonstrate exceptional performance and chip control in automotive part production made of AISI 430 Nb (ferritic) stainless steel
Chip control is one of the most prominent variables in shopfloor efficiency as cutting chip related problems are the root causes of defective parts, shortened tool life, poor surface finish, among others. These concerns are time-consuming to resolve and can significantly impact hours of production time. By taking control of cutting chips, machining time and downtime can be minimized even in small lot production to reduce overall manufacturing cost.
Headquartered in Casterlfidardo, Ancona, Italy, Guerrini Industry S.p.A. is a leading manufacturer of precision turned metal parts.
The elimination of cutting chip problems and achieving stable long tool life in its clamping nut production are some of the key objectives of Guerrini Industry S.p.A. (Guerrini), a leading manufacturer of precision turned metal parts. Headquartered in Casterlfidardo, Ancona, Italy, Guerrini was originally founded in 1962 as a small artisan company. Over the years, Guerrini has evolved into a major national company in the precision turning of small metal parts, servicing various sectors including automotive, electromechanics, hydraulics, appliances, and more. Automotive in particular, is a key sector for Guerrini and currently represents more than 50 percent of the company’s turnover.
Guerrini employs approximately 80 staff at its 7,500-square-meter production plant with 80 machines, 60 of which are CNC lathes.
Today, Guerrini employs approximately 80 staff at its 7,500-square-meter production plant with 80 machines, 60 of which are CNC lathes. Guerrini’s constant growth is contributed by the quality of its products, which has allowed the company to obtain important certifications, as well as continuous expansion and investment in cutting-edge technology to offer customers flexibility, speed, reliability and timely delivery. In addition, Guerrini stands out for the possibility of complete project management thanks to a vast and consolidated fleet of qualified and certified suppliers. The ability to guarantee a total solution and a single point of contact for all aspects of the order saves the customer from an additional step to complete the production chain, which is optimized to the maximum.
Custom clamping nuts made of AISI 430 Nb (ferritic) stainless steel. The production capacity of Guerrini’s plant is estimated to be around 1,500,000 pieces annually.
Recently, Guerrini was looking to improve chip control and tool life on a custom clamping nut production developed for a client in the automotive sector. The production capacity of Guerrini’s plant is estimated to be around 1,500,000 pieces annually based on statistics from 2020, with lot size averaging between 80,000 to 120,000 pieces. The turned pieces are made of AISI 430 Nb (ferritic) stainless steel and require the machining of one M12 x 1.5 blind hole at a depth of 10.4 mm per part. The pre-drilled hole size is 10.6 mm in diameter. An INDEX MS32 CNC multi-spindle machine is used for the processing.
Guerrini uses an INDEX MS32 CNC multi-spindle machine for the processing of its clamping nut production made of AISI 430 Nb stainless steel.
Originally, Guerrini was using a competitor drill and tap for the application and experienced chip control problems and poor tool life. In search of improvement, Guerrini CNC Production Managers Fabrizio Tavoloni and Nicolò Tavoloni contacted OSG through Tecnomeccanica Tools, a distributor in Jesi, to optimize performance.
An inside view of the INDEX MS32 CNC multi-spindle machine.
Shortly after, OSG Italia Engineering Manager Andrea Severi and OSG Italia Sales Representative Alfredo Nadini visited Guerrini’s production facility to evaluate the application. After analyzing the cutting condition, the dual recommended using OSG’s 10.6 mm diameter ADO-SUS-3D drill (EDP# 8681060) and a M12 x 1.5 Z-SFT spiral-fluted cutting tap (EDP# 48029176). Both tools are mounted on an ER25 clamp holder spindle. Oil is used for the coolant.
ADO-SUS Carbide Drill
The ADO-SUS coolant-through carbide drill is one of OSG’s latest innovations engineered to excel in stainless steel and titanium alloy applications.
The ADO-SUS coolant-through carbide drill is one of OSG’s latest innovations engineered to excel in stainless steel and titanium alloy applications. This drill series has adopted a tool geometry that emphasizes sharpness to reduce work hardening, thereby prolonging tool life for post-processing including reaming and tapping. Its unique flute form encourages the creation of small cutting chips, which is essential for trouble-free chip evacuation. Furthermore, the ADO-SUS has employed a unique oil hole design “MEGA COOLER” for diameter sizes above 6 mm to suppress heat generation and to facilitate smooth chip evacuation. With the addition of OSG’s WXL coating, which has strong adhesion strength, high resistance against welding can be achieved. Utilizing OSG’s latest cutting tool technology, the ADO-SUS series is capable of drilling stainless steel and titanium alloy with predictable and consistent tool life, making efficient machining of difficult-to-machine materials a reality.
Z-SFT Spiral Tap
The Z-SFT is a powder metal spiral-fluted cutting tap designed for high-speed tapping in general steel and stainless steel with excellent chip control.
A part of OSG Europe’s high performance Z series, the Z-SFT is a powder metal spiral-fluted cutting tap. Coated with multilayer TiCN coating, the Z-SFT is designed for high-speed tapping in general steel and stainless steel with excellent chip control.
Guerrini was looking to improve chip control and tool life on a custom clamping nut production developed for a client in the automotive sector. The turned pieces are made of AISI 430 Nb (ferritic) stainless steel and require the machining of one M12 x 1.5 blind hole at a depth of 10.4 mm per part.
For the machining, the parameters used for the tools are identical to those of the competitor tools. The ADO-SUS carbide drill is used at a cutting speed of 50 m/min and a feed rate of 0.14 mm/rev. In terms of tool life, the competitor drill was able to complete 20,000 holes. The ADO-SUS, on the other hand, completed 90,000 holes before retiring. For the tapping process, a cutting speed of 15 m/min is used. The competitor tap had a tool life of 15,000 holes whereas the Z-SFT is able to process 45,000 holes before wearing out.
From left, Tecnomeccanica Tools Owner Piergiorgio Cervone, Guerrini Industry S.p.A. Production Manager Fabrizio Tavoloni, Guerrini Industry S.p.A. Production Manager Nicolò Tavoloni, and OSG Italia Engineering Manager Andrea Severi pose for a photograph at Guerrini’s manufacturing facility in Casterlfidardo, Ancona, Italy.
Under identical cutting condition, OSG’s ADO-SUS drill is able to produce 4.5 times more pieces while the Z-SFT is able to last 3 times longer versus the competition in durability. In addition to the prolonged tool life, the production process has also become more stable, with no machine downtime caused by cutting chip problems. Perfect chip control eliminates potential damage to the part surface and cutting tool, as well as decreases tool setup time thanks to long tool life. By taking complete control of cutting chips, Guerrini is able to optimize its clamp nut production, reduce costs and maximize manufacturing efficiency.
For more information on OSG’s ADO-SUS carbide drill series, OSG Italia, and Guerrini Industry S.p.A.
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