OSG’s 100xD drill redefines performance standards in mold manufacturing
In modern mold manufacturing, where maximum efficiency is essential, deep hole drilling has long been regarded as a bottleneck that restricts production cycles. Recently, the engineering team at OSG Shanghai (OSG China), working with a globally recognized die‑casting manufacturer, overcame the challenge of ultra‑deep hole drilling in SKD61. In this project, OSG broke the longstanding reliance on conventional gun drilling and achieved 100xD deep hole machining with the solid carbide ADO‑100D drill. The accomplishment not only raises industry expectations for deep hole drilling but also delivers significant efficiency gains for the customer.
Yutaka Annoue, OSG product development engineer and project manager, holds a 3‑mm‑diameter ADO‑100D ultra‑long deep hole drill developed with his team at OSG Shanghai to enhance machining efficiency in ultra‑deep hole drilling of large die‑cast molds made from pre‑hardened SKD61.
Industry Background and Customer Challenges
Established in 2005, the customer featured in this project is a major mold manufacturer in Northern China whose name is withheld for confidentiality. The company operates a 140,000‑square‑meter facility and employs about 2,000 people. It serves as a benchmark producer of core automotive components, including transmission cases and cylinder blocks. Its mold shop had traditionally relied on gun drilling for hot‑runner holes in large die‑cast molds made of pre‑hardened SKD61. Although gun drills provide excellent straightness, their low machining efficiency remained a major obstacle to expanding production capacity.
The workpiece for this project measured 300 mm by 400 mm by 400 mm and required deep hole drilling to create complex internal channels in SKD61. Standard solid carbide deep hole drills typically max out around 50xD, and even special‑order options rarely exceed 70xD. Surpassing those limits to achieve high‑efficiency 100xD machining presented a significant technical challenge for OSG.
Breaking Conventional Wisdom: The Birth of the 100xD Solution
Faced with this challenge, OSG’s engineering team, led by project manager Yutaka Annoue, moved beyond conservative approaches and proposed an innovative solution using a 3‑mm‑diameter ADO‑100D ultra‑long deep hole drill.
The ADO coolant-through carbide long drill series is one of OSG’s latest drilling innovations for ultra-efficiency in deep-hole applications.
OSG’s ADO coolant‑through carbide drill series features a proprietary R‑gash geometry designed for extremely low cutting resistance and excellent chip control. This geometry generates compact, tightly curled chips that evacuate reliably even in deep‑hole conditions. The series also incorporates a specialized flute design that improves chip evacuation and enhances tool rigidity. Additionally, the drills are coated with OSG’s original EgiAs coating, which provides high toughness and resistance to heat and wear, ensuring consistent, stable tool life.
To prevent vibration or breakage of the slender drill and to maintain smooth chip evacuation, the team collaborated with OKK (machine tools) and NT Tool (hydro chucks). With support from NX software, they developed a detailed “4‑Step Machining Strategy.”
The strategy is built around a staged approach with precise tool guidance:
Step 1: High‑Precision Pilot Hole Machining
A 6.5‑mm‑diameter pilot hole is machined to a depth of 20 mm to establish an accurate reference position for all subsequent operations.
Step 2: Relief (Counterbore) Machining for Load Reduction
A 6.5‑mm‑diameter counterbore is machined to a depth of 140 mm. This critical step reduces contact between the long shank and the hole wall, minimizing instability caused by frictional heat.
Step 3: Precision Introduction Guide
Using a special 3‑mm‑diameter guide drill, a 6‑mm‑deep guide hole is machined at the bottom of the counterbore. This creates an ideal entry point for the 100xD drill and ensures stability as soon as the cutting edge engages the material.
Step 4: Continuous Deep Hole Drilling
With all preparations complete, the ADO‑100D deep hole drill completes the remaining depth in a single continuous pass. The drill’s geometry and rigidity enable stable, uninterrupted machining.
Results and Outlook
On‑site testing and production trials confirmed that the solution offers exceptional machining stability. Compared with traditional gun drilling, OSG’s 100xD solid carbide drill significantly improved cutting speed and feed rates while maintaining smooth chip evacuation and excellent hole‑wall quality.
The success of this project demonstrates not only the advanced performance of the ADO series in ultra‑deep hole applications but also OSG’s ability to integrate machine tools, cutting tools and digital platforms into a comprehensive total solution for complex machining environments. Looking ahead, OSG will continue to push technological boundaries with the “Spirit of 100xD,” driving new levels of efficiency in the mold manufacturing industry.
For more information on the ADO coolant-through carbide drill series, customized order and OSG Shanghai
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