The new standard for hard and brittle material processing
Hirofumi Inayoshi | OSG Corporation
Hard & Brittle Materials
Hard and brittle materials such as cemented carbide, ceramics and quartz glass offer incredible wear resistance and heat resistance. With material properties that cannot be met by metal or plastic-based materials, hard materials are increasingly applied in a wide range of industries such as automotive, mechatronics, chemical, medical, aerospace, and more. The use of cemented carbide, ceramics and quartz glass in particular has elevated year by year in the mold and semiconductor sectors to improve precision and durability of components.
Although hard materials are ideal for many applications, they can be weak against impact and can break unpredictably due to their brittle characteristic. In addition, the processing of hard materials is highly challenging, requires a lot of time, and the tools used are subject to severe wear, making it an expensive production process. High tool wear and ensuring that the required level of precision is met while keeping machining cost low are some of the common obstacles of processing hard and brittle materials.
Grinding has been the standard technology used for machining hard and brittle materials. For materials that are electrically conductive, electrical discharge machining (EDM) is also used. These methods, however, often require long cycle time and many processing steps.
6C x OSG
To enhance cost efficiency in the processing of hard and brittle materials, OSG Corporation has partnered with 6C Tools AG in 2022 and established the 6C x OSG brand.
Founded in 2015, 6C Tools AG (6C) is a tool manufacturer based in Zurich, Switzerland. 6C, which manufactures cutting tools using solid polycrystalline diamond (PCD) as a base material, is a startup company that supplies products to precision processing manufacturers in Switzerland and abroad.
Established in 1938, OSG Corporation is one of the world’s leading comprehensive cutting tool manufacturers. OSG holds the No. 1 position in the Japanese cutting tool market as well as a top-ranking position globally, with a production, sales and technical network spanning more than 30 countries. OSG’s world-class R&D facilities and laboratories are staffed by highly trained engineers, all dedicated to developing the highest quality products using environmentally friendly processes. OSG has traditionally maintained a powerful marketing presence in manufacturing industries including automotive, aerospace and mold and die. OSG also supplies products to energy-related industries, the construction equipment industry, as well as to the manufacturers of micro precision equipment that requires high machining accuracy, such as semiconductors for 5G, precision molds, mobility, and robotics.
6C x OSG is a cutting tool series optimized for the processing of hard and brittle materials with high precision and good surface finish at a new level of geometric complexity. The 6C x OSG brand proposes a new concept for machining free-form shapes out of hard, brittle materials without the drawbacks of both grinding and EDM. PCD tools by 6C x OSG enable direct machining that is highly efficient and accurate, which shortens machining time, reduces costs, minimizes energy consumption, and contributes to the realization of carbon neutrality.
Product Overview
PCD Drill “PCD-MXD”
The PCD-MXD is composed of solid PCD engineered for long tool life in the drilling of hard and brittle materials. Its unique w angle geometry prevents chipping on the tool and workpiece. Furthermore, its low helix flute form improves tool rigidity, making it ideal for machining hard and brittle materials such as cemented carbide, ceramics and quartz glass.
Machining Example
The average tool life of a conventional diamond coated drill in silicon carbide is around 30 holes. As depicted in figure 1, the PCD-MXD demonstrates superior tool life by completing 120 holes with a single tool in silicon carbide and can continued to be used.
Figure 1. Silicon carbide processing example: drilling 120 holes with a single tool
PCD Radius End Mill “PCD-MRM”
The PCD-MRM is composed of solid PCD engineered for long tool life in the milling of hard and brittle materials. Its ultra multi-flute configuration makes roughing highly efficient while enabling a mirror finish. By featuring a helix flute geometry, cutting resistance is minimized. The PCD-MRM is suitable for hard and brittle materials such as cemented carbide, ceramics and quartz glass.
Machining Examples
As illustrated in figure 2, the PCD-MRM demonstrates high machining efficiency by removing a volume of 380 mm3 in cemented carbide in just four and a half minutes with normal wear progression and can continued to be used.
Figure 2. Shape processing of cemented carbide: removes a volume of 380 mm3 in just four and a half minutes
Figure 3 depicts the PCD-MRM’s capability to complete roughing to mirror finishing in cemented carbide with a single tool.
Figure 3. Mirror finishing of cemented carbide: completes roughing to mirror finishing with just one tool
PCD Chamfering Tool “PCD-MCM”
The PCD-MCM is composed of solid PCD engineered for long tool life and high machined surface quality even in hard and brittle materials that are prone to chipping. By featuring a multi-flute configuration, machining efficiency is enhanced. The PCD-MCM is suitable for hard and brittle materials such as cemented carbide, ceramics and quartz glass.
Machining Example
As depicted in figure 4, the PCD-MCM is able to achieve both machining efficiency and good machined surface quality even in quartz glass.
Figure 4. Chamfering of quartz glass: achieves good machined surface quality even in quartz glass
PCD Thread Mill “PCD-MTM”
The PCD-MTM is composed of solid PCD engineered for long tool life in the threading of hard and brittle materials. By featuring a multi-flute configuration, machining efficiency is enhanced. Furthermore, its single thread form reduces cutting resistance and minimizes the pitch diameter difference between the hole entry and inner hole. The PCD-MTM is suitable for hard and brittle materials such as cemented carbide, ceramics and quartz glass.
Machining Examples
As depicted in figure 5, the PCD-MTM demonstrates five times the processing efficiency versus a conventional tool in internal thread milling of Zirconia. In addition to the reduction of cycle time, good thread quality is also achieved.
Figure 5. Internal thread milling in Zirconia: 5 times the machining efficiency
Figure 6 is an internal thread milling example in quartz glass. The PCD-MTM demonstrates high machining efficiency and good thread quality.
Figure 6. Internal thread milling in quartz glass: achieves high-quality threads even with high-efficiency machining
As a new standard for the processing of hard and brittle materials, 6C x OSG proposes innovative machining technology that does not compromise on processing quality and production efficiency.
6C x OSG products are currently available in Japan, China and Taiwan. For more information on 6C x OSG (Japanese only)
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