ADO-SUS carbide drill demonstrates superior cutting performance at high feed rates to elevate productivity in hydraulic and pneumatic component production made of 316L stainless steel for the oil and gas industry
Consistent cutting tool performance plays a crucial role in manufacturing. When processing efficiency and stability are maintained without compromising quality, significant cost savings can be achieved even in small batch production.
Headquartered in Lurano, Bergamo, Italy, Simtech S.r.l. specializes in the production of parts made by mechanical turning and milling processes for the field of hydraulics and pneumatics.
The elimination of cutting chip problems and the minimization of tool wear in stainless steel component production are some of the key objectives of Simtech S.r.l., a part manufacturer headquartered in Lurano, Bergamo, Italy. Established in 2003, Simtech today employs 22 staff in its 3,000-square-meter production plant. Simtech specializes in the production of parts made by mechanical turning and milling processes for the field of hydraulics and pneumatics. Simtech’s manufacturing plant is equipped with numerous numerical control machining centers where the company can optimize work cycles of parts for small, medium and large batches in various materials, such as quenched and carbon steel, stainless steel, cast iron and aluminum. The production capacity of the Simtech plant is estimated to be around 20,000 parts annually, with a mix of distributors and pressure reducers divided into 10 types of products.
Simtech’s 3,000-square-meter manufacturing plant is equipped with numerous numerical control machining centers where the company can optimize work cycles of parts for small, medium and large batches in various materials.
Since the company’s founding more than 20 years ago, Simtech has followed strict internal procedures to maintain all phases of its process under control. In 2008, Simtech was certified by the Certiquality Certification Institute for the ISO:9001 standard. With its team of specialists and by leveraging the latest machinery and cutting-edge processing tools, Simtech today services leading Italian and foreign companies operating in various industries. The quality of service, competence, and professionalism combined with the collaborative relationship with partners as well as customers have been keys to Simtech’s growth over the years.
The pressure reducers are machined using a Haas VF-3 vertical machining center.
As a company that is attentive to new technologies, Simtech is always actively seeking for process optimization. Recently, Simtech was looking to improve tool performance on the production of two components made of 316L stainless steel. The first part is a pressure reducer for regulating the pressure of oxygen and fluids. It is produced in batches of 500 pieces with an annual production volume of 2,000 pieces. Each pressure reducer requires the drilling of 20 blind holes in two sizes and six through holes in three sizes. The second part is a hydraulic distributor, a key component in hydraulic systems. It is produced in batches of 100 pieces with an annual production volume of 1,000 pieces. Each hydraulic distributor requires the drilling of 12 blind holes in two sizes and five through holes at a diameter of 13 mm. The parts are machined using a Haas VF-3 vertical machining center.
A pressure reducer made of 316L stainless steel used for regulating the pressure of oxygen and fluids. Each pressure reducer requires the drilling of 20 blind holes in two sizes and six through holes in three sizes. The following are used for drilling this component: ADO-SUS-5D Dia. 3.66 EDP# 8667366 – (8 blind holes, Ap=10mm), Vc=80 m/min – F=0.11 mm/rev; ADO-SUS-3D Dia. 4.65 EDP# 8680465 – (12 blind holes, Ap=12mm), Vc=80 m/min – F=0.14 mm/rev; ADO-SUS-5D Dia. 5.3 EDP# 8667530 – (2 through holes, Ap=24mm), Vc=80 m/min – F=0.16 mm/rev; ADO-SUS-3D Dia. 8.5 EDP# 8680850 – (2 through holes, Ap=12mm), Vc=80 m/min – F=0.23 mm/rev; ADO-SUS-3D Dia. 11.4 EDP# 8666140 – (2 through holes, Ap=24mm), Vc=80 m/min – F=0.25 mm/rev
To ensure night production in an unattended and automated fashion, the tool life of the drill has been set to 500 parts. At the end of the batch, drills that are still in good condition are removed from the automated work cycle and used for other processes. Simtech was originally using several competitor drills for these two applications. However, the competitor drills exhibited excessive wear of the cutting edge in the peripheral area, resulting in the generation of long cutting chips that caused downtime after only 100 to 150 parts.
A hydraulic distributor made of 316L stainless steel, a key component in hydraulic systems. Each hydraulic distributor requires the drilling of 12 blind holes in two sizes and five through holes at a diameter of 13 mm. The following are used for drilling this component: ADO-SUS-3D Dia. 4.65 EDP: 8680465 – (8 blind holes, Ap=12mm), Vc=80 m/min – F=0.14 mm/rev; ADO-SUS-3D Dia. 5.55 EDP: 8680555 – (4 blind holes, Ap=12mm), Vc=80 m/min – F=0.14 mm/rev; ADO-SUS-3D Dia. 13 EDP: 8681300 – (5 through holes, Ap=27mm), Vc=80 m/min – F=0.25 mm/rev
Seeking to optimize process stability, increase tool life and improve chip control that caused enormous downtime, Simtech Production Manager Andrea Manzoni contacted OSG through Uciemme in Caravaggio, Bergamo, a local distributor. Shortly after, Uciemme Manager Osvaldo Centurelli and OSG Italia Engineering Manager Andrea Severi visited Simtech’s manufacturing facility to evaluate the application. After analyzing the cutting condition, Severi recommended OSG’s ADO-SUS coolant-through carbide drill series.
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. 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.
The ADO-SUS coolant-through carbide drill is one of OSG’s latest innovations engineered to excel in stainless steel and titanium alloy applications.
Unlike the competitor tools, the ADO-SUS drill is able to complete 500 parts without problems of instability and chip control, which is always short and fragmented. Thanks to the ADO-SUS carbide drill’s special margin shape, sharp cutting edge, unique flute geometry and the patented WXL coating, friction and heat development are drastically reduced, thus significantly increasing tool life by more than three times versus the previous tooling choice. Considering the low coolant concentration of 6 percent (Quaker Houghton Hocut 3130), the increase in tool life has been truly remarkable, contributing to better management of tool purchases and a reduction in machining costs.
From left, OSG Italia Engineering Manager Andrea Severi, Simtech Production Manager Andrea Manzoni, and Uciemme Manager Osvaldo Centurelli pose for a photograph at Simtech’s manufacturing facility in Lurano, Bergamo, Italy.
The ADO-SUS has proven to be the winning cutting tool of choice, with exceptional ability to produce short and compact cutting chips even in difficult-to-machine material such as stainless steel, guaranteeing extreme stability at high cutting parameters to elevate productivity.
For more information on OSG’s ADO-SUS carbide drill series, OSG Italia, and Simtech S.r.l.
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