Environmentally Friendly Products

OSG promotes large-scale efforts to contribute to carbon neutrality starting with its cutting tools

Arina Kobayashi | OSG Corporation

In recent years, awareness of environmentally friendly efforts toward the realization of a sustainable society has drastically increased. The Japanese government has set a goal of achieving carbon neutrality by 2050, and is promoting various initiatives such as energy conservation and the adaptation of low-carbon lifestyles. Resource conservation has become today’s norm, and we are required to make environmentally conscious choices not only in the industrial sectors, but also in our daily lives. As a comprehensive cutting tool manufacturer that provides responsible products, OSG proposes tooling solutions from an environmentally friendly perspective, focusing on energy saving, waste reduction by minimizing tool usage, and improvement of the machining environment.

Environmental Impact of Cutting Tool Selection

Cutting tools and the environment may seem unrelated at first glance. However, when cutting materials such as metals, electricity is consumed, and carbon dioxide (CO2) is emitted when electricity is generated. Consequently, by reducing power consumption, CO2 emissions can also be reduced. In addition, the main raw materials of cemented carbide used as the base material of cutting tools are rare metals. There are concerns when mining rare metals, such as destruction of the earth’s surface and environmental pollution due to chemicals generated when rare metals are smelted. By opting for high-performance cutting tools, processing efficiency and machine tool availability can be improved, which minimizes power consumption. Additionally, by extending tool life and reconditioning used tools, the amount of cemented carbide waste can be lessened, which are essential factors for contributing to carbon neutrality.

Selecting products manufactured with consideration for the environment contributes to reducing environmental impact. Using the following cutting examples, we will highlight some of OSG’s latest environmentally friendly products.

A-XPF Highly Efficient and Multi-purpose Forming Tap

First, we will introduce machining improvements by using the A-XPF highly efficient and multi-purpose forming tap (figure 1). Table 1 summarizes common tapping trouble consultations received at OSG’s customer service center. In all cases, the main cause of trouble is cutting chip related. As depicted in figure 2, forming taps form threads by plastic deformation of the work material. Therefore, no chips are generated during tapping. By leveraging the A-XPF, troubles caused by chips can be completely eliminated, which prolongs tool life. Reducing tool usage through longer tool life also leads to less waste. In addition, the A-XPF reduces tool change time due to chip troubles and machine stop time when removing accumulated chips, making it possible to shorten machining cycle time and reduce power consumption.

Figure 1. A-XPF highly efficient and multi-purpose forming tap. The A-XPF is engineered with a special thread shape that improves cutting edge rigidity. In addition, by employing a high-performance VI coating exclusively designed for taps, high-load machining is made possible.

Table 1. Top 3 tapping troubles (source: OSG Technical Consultation Division)

Figure 2. Chip evacuation visual image of cutting tap and A-XPF

ADO-MICRO Small Diameter Coolant-through Carbide Drill

Next, we will introduce the ADO-MICRO (figure 3), a small diameter coolant-through carbide drill that contributes to waste reduction by stable and high efficiency drilling in deep-hole applications, which are highly difficult to machine. One of the keys for successful small diameter deep-hole drilling is trouble-free chip evacuation. The ADO-MICRO features a straight hollow shank design where coolant is injected in addition to the two spiral oil hole paths. This configuration increases coolant discharge from the tool tip. With a higher coolant flow rate, cutting chips can be more effectively evacuated, thereby enabling stable machining. Furthermore, the ADO-MICRO employs a unique double margin geometry to enable stable machining by smoothly discharging the micro sludges that tend to accumulate on the outer periphery of the cutting tool, which is a key cause of abrupt tool breakage.

Figure 4 depicts a cutting example in SUS304 using a diameter 0.7 mm ADO-MICRO-5D drill. While the competitor product exhibited chisel wear after machining 600 holes, the ADO-MICRO was able to continue drilling even after 1,800 holes. Additionally, due to the effect of the straight hollow shank design, the amount of coolant discharged per minute is approximately five times that of the competitor product. One piece of drill requires approximately 7 grams of cemented carbide. The competitor drill required three times the number of tools to complete 1,800 holes versus the ADO-MICRO, thus requiring 21 grams of cemented carbide. By using a third of the tooling, the ADO-MICRO is able to reduce cemented carbide waste by approximately 65 percent and contribute to waste reduction with long tool life.

Figure 3. ADO-MICRO small diameter coolant-through carbide drill. Good chip evacuation enables stable and highly efficient machining of small diameter deep holes. Stable machining of small diameter deep holes leads to longer tool life.

Figure 4. Cutting example in SUS304

AE-VMS Anti-vibration Carbide End Mill

Next, we will introduce the AE-VMS anti-vibration carbide end mill (figure 5), which is certified by the Japan Cutting & Wear-resistant Tool Association (JTA) as an environmentally friendly product. The AE-VMS employs OSG’s original DUARISE coating with excellent lubricity, wear resistance, and high temperature oxidation resistance, enabling stable durability regardless of coolant. Figure 6 depicts a cutting example with a 6 mm outer diameter AE-VMS end mill in SCM440 using air-blow. Compared to the competitor products, the AE-VMS is able to achieve minimal wear and stable machined surface roughness. Consistent durability and machining accuracy can be obtained even with air-blow, contributing to environmentally friendly processing.

Figure 5. AE-VMS anti-vibration carbide end mill. As the new milling standard, the AE-VMS is engineered with a unique flute form and coated with OSG’s original DUARISE coating, enabling good chip evacuation and excellent machined surface quality.

Figure 6. Cutting example in SCM440

AT-2 Carbide Thread Mill with End-cutting Edge for High-hardness Steels

Finally, we will introduce the AT-2 carbide thread mill with end-cutting edge (figure 7), which reduces machining processes and the number of tools required by performing helical drilling and threading simultaneously.

Generally speaking, the machining of high-hardness steel is highly difficult and often presents a risk of sudden tool breakage. As the number of machining process increases, the number of tools required also increases, and the risk of tool breakage escalates with each process. The AT-2 thread mill consolidates two processes into one by performing the conventional pilot hole drilling and thread cutting at the same time. Figure 8 shows a cutting example in SKD11 (60 HRC) using a diameter 6.2 mm x 16 P1.25 AT-2 thread mill versus a M8 x 1.25 3P carbide hand tap. With the hand tap, the cutting edge chipped after machining 65 holes. The AT-2, on the other hand, was able to process up to 208 holes with a single tool. The number of tools required to machine approximately 200 holes is less than one third that of the carbide hand tap, which reduces the amount of cemented carbide used by approximately 30 percent. Furthermore, the AT-2 eliminates the need for a carbide drill for pilot holes, making it possible to further reduce the amount of waste.

Figure 7. AT-2 carbide thread mill with end-cutting edge for high-hardness steels. By performing helical drilling and threading simultaneously, the consolidation of machining process in highly difficult high-hardness steel applications is made possible.

Figure 8. Cutting example in SKD11 (60 HRC)

OSG Environmentally Friendly Initiatives

In addition to supplying cutting tools, OSG is promoting tool reconditioning and carbide recycling throughout its network as environmentally friendly initiatives.

Tool Reconditioning

It is a general assumption that the cutting condition would be lowered after tool reconditioning. Production lines often would apply cutting conditions with consideration of the possibility of tool reconditioning in order to minimize changes in setup. Additionally, the pace of tool replacement may become sooner than needed due to the presumed inferior tool durability. At OSG, we make full use of the tool design know-how and coating technology that we have cultivated over many years as a comprehensive tool manufacturer, and are able to restore used tools equvalent to new condition. Since the performance and durability are identical as new products, cutting conditions can be improved and tool life can be extended.

Carbide Recycling

Carbide tools that can no longer be reground can be collected and recycled through the OSG Group’s recycling program. Cemented carbide materials contain a large amount of rare metals. Carbide recycling reduces material consumption, contributes to environmental preservation, and serves as a positive initiative for our customers’ corporate social responsibility (CRS) activity in the promotion of zero emissions.

Making a difference starting from cutting tools, OSG will continue to develop innovative products, propose efficient processing techniques, and provide optimium services to contribute to the earth’s sustainability and carbon neutrality.

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