Composite Tool Selection Guide - OSG Tooling Australia · 2016-02-22 · 2 1. N1 - Reaming is...

2

1. N1 - Reaming is Required 2. N2 - Step Feed is Required

Thin ≤ .100" and 0.2xD

Composite Tool Selection Guide

Machining Style Machining Efficiency

Machine Type Composite Type

Tool Slotting Side Milling Roughing Finishing Hand CNC 5-Axis or

Robot Thin Thick

AERO-BNC

AERO-HBC xAERO-REC xAERO-MFR x x xAERO-CFR

Electroplated Style x x x x

Machine Type Composite Type

Tool Hand Pneumatic CNC CFRP Honeycomb (Nomex) CFRP/Al Stack CFRP/Ti

StackCFRP/CRES

Stack

Com

posi

te

AERO-STAD x xAERO-LHX x x x x xAERO-DAD x x 2 x xD-REAMER x x xDREAMER x x x

Sta

ck Type N x 1 x xType H x x x

GoodOKNot Recommended Bestx

GoodOKNot Recommended Bestx

Routers Pictured (Left to Right): BNC, HBC, REC, MFR & CFR

Drills Pictured (Left to Right): TAD, LHX, DAD, TYPE N & TYPE H

The Patented Ultra-Fine Grain Size

OSG Ultra-Fine Diamond Coating

OSG Ultra-Fine Diamond Coating

Before Regrinding

Competitor Diamond Coating(Industry Standard)

Diamond Delamination (Note: Large Grain Size)

After Regrinding

Elimination of Diamond Delamination

Capability of Regrinding Diamond Coated Drills

Advantage #1

Advantage #2

Advantage #3

3

The Aerospace Industry's mission is to manufacture more environmentally progressive, longer range and faster aircrafts that require lower operating costs. OSG's cutting tools share the same mission.

All of OSG's composite tooling feature exclusive metallurgy and cutting geometries to help increase productivity, reliability and tool life while reducing machining time and scrap. OSG also offers a patented ultra-fine diamond coating, which is a prerequisite when machining composites and provides a definitive advantage over other competitor diamond coated products.

OSG’s patented ultra-fine diamond coating has a maximum diamond grain size diameter of 2μm. This strictly controlled diameter allows our coating to be super smooth and extremely sharp, which visually is easily distinguishable from our competition.

Unlike our competition, OSG manufactures all diamond products in-house. This includes using our grinding techniques on our special carbide substrate. The end result is a diamond coated product in which tool life can be consistently predicted, rather than having to endure premature diamond delamination like most of our competition.

In order to provide the best valued tool, OSG also offers regrinding and recoating service for our diamond coated drilling products. This service allows us to increase the yield ratio of our tools and reduces overall machining costs for our customers.

OSG's Ultra-Fine Diamond Coating: The Industry's Best

The OSG Advantage

Fine Pitch Nicked Router - Diamond Coated

Type 2Type 1

Type 4Type 3

Packed: 1 pc. Available Diamond coating only.Type 1: No End Cut, Type 2: Bur End, Type 3: End Mill Cut, Type 4: Drill Point (Available as special only)

Note: This table’s parameters are based on common material thickness of approximately 0.250” under excellent workholding conditions and less than 20% x D depth of cut (side milling). Please adjust your parameters properly for your application or call OSG for assistance. Conventional milling is recommended for better surface finishes. Higher feed rates are possible but quality of part and surface should be considered.

Feed Reduction: Recommended feed adjustments based on thickness of part.(Above table is based on approximately 1xD thickness.)

≤0.5D x 150%0.5D-1D x 120%

1D-2D x 80%3D-4D x 50%

4

List 2061

EDP NumberMill Dia. Length of Cut OAL Shank Diameter

No. of Flutes TypeD Lc L d

20610116 1/8 1/4 1 1/2 1/8 6 220611116 1/8 3/8 1 1/2 1/8 6 320612116 1/8 1/2 1 1/2 1/8 8 320610216 3/16 3/8 2 3/16 6 220611216 3/16 9/16 2 3/16 6 320612216 3/16 3/4 2 3/16 8 320610316 1/4 1/2 2 1/2 1/4 8 220611316 1/4 3/4 2 1/2 1/4 10 320612316 1/4 3/4 2 1/2 1/4 10 220613316 1/4 1 3 1/4 10 320614316 1/4 1 3 1/4 10 220615316 1/4 1 1/4 4 1/4 12 120610416 5/16 1 2 1/2 5/16 10 320610516 3/8 3/4 2 1/2 3/8 12 220611516 3/8 1 1/8 3 3/8 12 320612516 3/8 1 1/8 3 3/8 12 220613516 3/8 1 1/2 4 3/8 12 320614516 3/8 1 1/2 4 3/8 12 220615516 3/8 2 4 3/8 12 120610716 1/2 1 3 1/2 14 320611716 1/2 1 3 1/2 14 220612716 1/2 2 4 1/2 16 2

EXOPRO®-AERO-BNC

Recommended Cutting ConditionsSide Milling Slotting

SFM 400 800 300 600

Depth of Cut Aa: Up to 1.5D / Ar: Up to 1D Aa: 1D

Dia. RPM Feed RPM Feed RPM Feed RPM Feed 1/8 12000 20 24000 40 9000 10 18000 20

3/16 8000 25 16000 50 6000 12 12000 25 1/4 6000 30 12000 60 5000 15 9000 30

5/16 5000 35 10000 70 4000 18 7000 35 3/8 4000 40 8000 80 3000 20 6000 40 1/2 3000 50 6000 100 2000 25 5000 50

5

The EXOPRO®-AERO-BNC is a patented diamond coated fine nicked router

specifically designed for carbon fiber composite trimming. The router features

a patented cutting geometry coupled with OSG's patented diamond coating.

Although the details of the machining conditions cannot be disclosed, our products achieved approximately four times the tool life versus the competitor product (from company S).

Pictured on left: End trimming of a CFRP stringer.

w Patented nick & flute form to eliminate uncut fibers & delamination

w Extremely low cutting forces/ long tool life

w Flute management can be applied

w Best in carbon fiber, also good for carbon/carbon and honeycombs

w High feed roughing and finishing

w Applied in both thick and thin laminates

w End cuts for plunging and face trimming

w Type 2 is for ramping & helical interpolation Type 3 is for plunging and helical interpolation

Features

ApplicationsPerformance Highlights

0

50

100

150

200

Mill

ing

Leng

th (

ft)

OSG EXOPRO®-AERO-BNC

3/8”

Competitor S(DiamondCoated)

Tool Life Comparison

w By utilizing Flute Position Management*, tool life can be increased.

Flute Management

*To change the milling position at the flute

Packed: 1 pc. Available Diamond coating only.

Herringbone Router - Diamond Coated



Feed Reduction by Thickness of Part: Recommended feed adjustments based on thickness of part. (Above table is based on approximately 1xD thickness.)

≤0.5D x 150%0.5D-1D x 120%

1D-2D x 80%3D-4D x 50%

6

List 2066

EDP NumberMill Diameter Compression Length Length of Cut OAL Shank Diameter No. of

FlutesD L2 Lc L d

20660116 1/8 0.125 3/8 1 1/2 1/8 420660316 1/4 0.250 3/4 2 1/2 1/4 420660516 3/8 0.375 1 1/8 3 3/8 420660716 1/2 0.500 1 1/8 3 1/2 4

EXOPRO®-AERO-HBC

Recommended Cutting ConditionsSide Milling Slotting

SFM 400 800 300 600


Dia. RPM Feed RPM Feed RPM Feed RPM Feed 1/8 12000 20 24000 40 9000 10 18000 20 1/4 6000 30 12000 60 5000 15 9000 30 3/8 4000 40 8000 70 3000 20 6000 35 1/2 3000 50 6000 100 2000 25 5000 50

Flute

Cutting Edge 4FL

4FL

8FL

Cutting Edge

6FL

6FL

6FL

6FL

6FLCutting

Edge

Flute

Flute

Cutting Edge 4FL

4FL

8FL

Cutting Edge

6FL

6FL

6FL

6FL

6FLCutting

Edge

Flute

7

ToolOSG - List 2066 Competitor

Herringbone Router - Diamond Coated

Material Carbon Fiber CompositeDiameter 0.500"

Number of Flutes 4 6

Milling Method Side Milling

Speed 6000 RPMFeed Various (24 to 480 IPM)DOC Aa: 0.250" / Ar: 0.125"

Coolant DryMachine VMC

The EXOPRO®-AERO-HBC is a diamond coated herringbone style router for high

feed rates and excellent surface finishes. The router features a compression cutting

mechanism along with OSG's patented diamond coating.

The EXOPRO®-AERO-HBC showed excellent performance and surface finished at high feed rates. The 4-flute herringbone design was able to mill up to 480 IPM without leaving streak marks on the composite.

OSG EXOPRO® AERO-HBC (List 2066)

Clean milling at 480 IPM

CompetitorStreaking and Torn/Uncut Fibers

w Compression mechanism to neutralize cutting forces to prevent delamination on both top and bottom laminates

w Low cutting forces/ long tool life

w Excels in carbon and glass composites and honeycombs

w High feed routing and finishing

w Best in thick laminates (Ref. L2 length on page 6)

w Excellent in thermoplastic matrix

Features

Applications

Performance Highlights


Roughing Router - Diamond Coated

Lc L

D


≤0.5D x 150%0.5D-1D x 120%

1D-2D x 80%3D-4D x 50%

8

List 2680

EDP NumberMill Diameter Length of Cut OAL Shank Diameter

No. of FlutesD Lc L d

26809316 15/64 3/4 2 1/2 1/4 426805316 1/4 1/2 2 1/2 1/4 426800316 1/4 3/4 2 1/2 1/4 426809416 5/16 15/16 3 3/8 626809516 23/64 1 1/8 3 3/8 626805516 3/8 3/4 3 3/8 626800516 3/8 1 1/8 3 3/8 626809616 7/16 1 15/16 3 1/2 826809716 31/64 1 1/2 3 1/2 826805716 1/2 1 3 1/2 826800716 1/2 1 1/2 3 1/2 8

EXOPRO®-AERO-REC

Recommended Cutting Conditions


Feed Reduction by Thickness of Part: Recommended feed adjustments based on thickness of part. (Above table is based on approximately 1xD thickness.)

Side Milling SlottingSFM 400 800 300 600


Dia. RPM Feed RPM Feed RPM Feed RPM Feed 1/4 6000 60 12000 180 5000 45 9000 90 3/8 4000 120 8000 240 3000 60 6000 120 1/2 3000 150 6000 300 2000 75 5000 150

0

500

1000

1500

2500

2000

Cut

ting

For

ce (

N)

OSGEXOPRO®-AERO-REC

OSGEXOPRO®-AERO-BNC

2211

976624

CompetitorHerringbone

6FL

Cutting Force Comparison

Comparison of Surface Finish

Router size: 0.3937"Coolant: DryMaterial: CFRP

Aa: 1" Ar: 0.3937"Cutting Speed: 656 SFMCutting Feed: 15.7 IPM

OSG EXOPRO®-AERO-REC

OSG EXOPRO®-AERO-BNC

CompetitorHerringbone

6FL

9

The EXOPRO®-AERO-REC is a diamond coated roughing router for roughing and semi-finishing of composites. The AERO-

REC uses extremely low cutting forces for low rigid fixtures and weak spindles.

Due to the roughing nick profile AERO-REC can reduce cutting force over competitor herringbone 6-flute and our AERO-BNC.

w Roughing nicks for efficient milling providing extremely low cutting forces

w Low rigid fixtures & setups and weak spindles

w Can be used in combination with AERO-MFR for finishing

Features

Applications



Flute Management



Finishing Router - Diamond CoatedFinishing Router - Diamond Coated

Lc L

D



Overhang RPM Reduction: Recommended feed adjustments based on thickness of part.(Above table is based on approximately 1xD thickness.)

≤0.5D x 150%0.5D-1D x 120%

1D-2D x 80%3D-4D x 50%

10

List 2650

EDP NumberMill Diameter Length of Cut OAL Shank Diameter

No. of FlutesD Lc L d

26500316 1/4 3/4 2 1/2 1/4 826501316 1/4 1 3 1/4 826500616 3/8 1 1/8 3 3/8 1226501516 3/8 1 1/2 3 3/8 1226500716 1/2 1 1/2 4 1/2 1426501716 1/2 2 4 1/2 14

EXOPRO®-AERO-MFR

Recommended Cutting ConditionsSide Milling

SFM 400 800

Depth of Cut Aa: Up to 1D / Ar: ≤ 0.2D

Dia. RPM Feed RPM Feed 1/4 6000 30 12000 120 3/8 4000 40 8000 140 1/2 3000 50 6000 200

Tool OSG List 2650

Competitor G Electroplated

Material Carbon / CarbonDiameter 5/16"

Milling Method Slotting

Speed 2700 RPM 9795 RPMFeed 50 IPMDOC Aa: 0.400"

Coolant Dry

0.0010 20,000 $50.00

$40.00

$30.00

$20.00

$10.00

$0.00OSG Competitor G

Total Tool Life Cost/Inch

Electroplated

15,000

10,000

5,000

0

0.0005

0.0000

-0.0005

-0.0010

-0.0015

-0.0020

-0.0025

-0.0030

Accuracy of Slot Milling Comparison of Cost

1st pass

Electroplated

2nd pass 3rd pass 4th pass

Competitor G OSG 1 OSG 2

Tape

r Mea

sure

men

t

Mill

ing

Leng

th (I

nch)

0.0010 20,000 $50.00

$40.00

$30.00

$20.00

$10.00

$0.00OSG Competitor G

Total Tool Life Cost/Inch

Electroplated

15,000

10,000

5,000

0

0.0005

0.0000

-0.0005

-0.0010

-0.0015

-0.0020

-0.0025

-0.0030

Accuracy of Slot Milling Comparison of Cost

1st pass

Electroplated

2nd pass 3rd pass 4th pass

Competitor G OSG 1 OSG 2

Tape

r Mea

sure

men

t

Mill

ing

Leng

th (I

nch)

11

w Multi fluted for super finishes

w Large core for ultra rigidity

w Excellent for tight tolerance & high precision applications

w Can be used in combination with AERO-REC for roughing

Features

Applications

The EXOPRO®-AERO-MFR is a highly rigid multi-fluted finishing router designed for high precision & accuracy requirements.

This router features a high rigid body with multi-flutes along with OSG's patented

diamond coating.

The AERO-MFR showed the best accuracy versus carbide diamond coated competition as well as electroplated products.



Flute Management


Standard Series, Stub Length, 2 Flute

List 7020

EXOCARB®-Diamond


EDP Number

MillDiameter OAL Length

of CutNeck

DiameterNeck

LengthShank

Diameter Coating Thickness

D L Lc d2 L1 d 12µm 20µm

70200016 1/64 1-3/4 3/64 0.015 3/32 1/8 F70200116 1/32 1-3/4 3/32 0.028 1/4 1/8 F70200216 3/64 1-3/4 3/16 0.040 1/2 1/8 F70200316 1/16 1-3/4 3/16 0.056 1/2 1/8 F70200416 5/64 1-3/4 1/4 0.070 1/2 1/8 F70200516 3/32 1-3/4 3/8 0.088 1/2 1/8 F70200716 1/8 1-3/4 1/2 — — 1/8 F70205716 1/8 1 3/4 1/2 — — 1/8 F70200816 5/32 2 9/16 — — 5/32 F70200916 3/16 2 3/4 — — 3/16 F 70201116 1/4 2-1/2 3/4 — — 1/4 F 70206116 1/4 2-1/2 3/4 — — 1/4 F70201316 5/16 2-1/2 13/16 — — 5/16 F 70201416 3/8 2-1/2 7/8 — — 3/8 F 70206416 3/8 2-1/2 7/8 — — 3/8 F70201616 1/2 3 1 — — 1/2 F 70206616 1/2 3 1 — — 1/2 F

12

Standard Series, Long Length, 4 Flute

Standard Series, Regular Length, 2 Flute, Ball End

List 7041

List 7010

EXOCARB®-Diamond


EDP Number


of CutShank

Diameter

D L Lc d

70410716 1/8 3 1 1/870410916 3/16 4 1 3/1670411116 1/4 4 1-1/2 1/470411416 3/8 4 1-1/2 3/870411616 1/2 5 2 1/2


EDP Number


of CutNeck

DiameterNeck

LengthShank

Diameter Coating Thickness

D L Lc d2 L1 d 12µm 20µm

70100116 1/32 1-3/4 3/32 0.028 1/4 1/8 F70100216 3/64 1-3/4 3/16 0.040 1/2 1/8 F70100316 1/16 1-3/4 3/16 0.056 1/2 1/8 F70100416 5/64 1-3/4 1/4 0.070 1/2 1/8 F70100516 3/32 1-3/4 3/8 0.088 1/2 1/8 F70100716 1/8 1-3/4 1/2 — — 1/8 F70105716 1/8 1-3/4 1/2 — — 1/8 F70100816 5/32 2 9/16 — — 5/32 F70100916 3/16 2 3/4 — — 3/16 F70101116 1/4 2-1/2 3/4 — — 1/4 F70106116 1/4 2-1/2 3/4 — — 1/4 F70101316 5/16 2-1/2 13/16 — — 5/16 F70101416 3/8 2-1/2 7/8 — — 3/8 F70106416 3/8 2-1/2 7/8 — — 3/8 F70101616 1/2 3 1 — — 1/2 F70106616 1/2 3 1 — — 1/2 F

13

Diamond Coated

Diamond Coated


EDP Number


of CutNeck

DiameterNeck

LengthShank

Diameter

D L Lc d2 L1 d

70400316 1/16 1-3/4 3/16 0.056 1/2 1/870400416 5/64 1-3/4 1/4 0.070 1/2 1/870400516 3/32 1-3/4 3/8 0.088 1/2 1/870400716 1/8 1-3/4 1/2 — — 1/870400916 3/16 2 3/4 — — 3/1670401116 1/4 2-1/2 3/4 — — 1/470401316 5/16 2-1/2 13/16 — — 5/1670401416 3/8 2-1/2 7/8 — — 3/870401616 1/2 3 1 — — 1/2

LcL1

L

��

��


EDP Number


of CutNeck

DiameterNeck

LengthShank

Diameter

D L Lc d2 L1 d

70300116 1/32 1-3/4 3/32 0.028 1/8 1/870300216 3/64 1-3/4 3/16 0.040 1/2 1/870300316 1/16 1-3/4 3/16 0.056 1/4 1/870300416 5/64 1-3/4 1/4 0.070 1/2 1/870300516 3/32 1-3/4 3/8 0.088 1/2 1/870300716 1/8 1-3/4 1/2 - - 1/870300916 3/16 2 3/4 - - 3/1670301116 1/4 2-1/2 3/4 - - 1/470301316 5/16 2-1/2 13/16 - - 5/1670301416 3/8 2-1/2 7/8 - - 3/870301616 1/2 3 1 - - 1/2

14

List 7040

List 7030

Diamond Coated End Mills

PFB (Inch & Metric)

Appearance Designation SpecificationNumber

of Cutting Edges

Insert Size EDP Number

Dc(inch)

R(inch)

T(mm)

H(mm) XC4505

Inse

rts

(Inc

h) PFB0375-D

Spiral Type (Diamond Coated)

2 0.375 0.1875 2.6 8.5 52101001PFB0500-D 2 0.500 0.250 3 10 52101002PFB0625-D 2 0.625 0.3125 4 12 52101003PFB0750-D 2 0.750 0.375 5 15 52101004PFB1000-D 2 1.000 0.500 6 18.5 52101005

Inse

rts

(Met

ric)

PFB080-D

Spiral Type (Diamond Coated)

2 8 4 2.4 7 7820020PFB100-D 2 10 5 2.6 8.5 7820021PFB120-D 2 12 6 3 10 7820022PFB160-D 2 16 8 4 12 7820023PFB200-D 2 20 10 5 15 7820024PFB250-D 2 25 12.5 6 18.5 7820025PFB300-D 2 30 15 7 22.5 7820026

15

φD

L

l1 l2

φd

φd2R

List 52100 & 78014

Ball End Indexable (PFB)

Steel Shank

EDP No. Body Type Designation

Tool Dia.(in)

Tool Rad.(in)

OAL(in)

Neck Length

(in)L/D

RatioNo. of Teeth

Shank Dia.(in)

Shank Length

(in)

Neck Dia.(in)

D R L l1 d l2 d2

List

52100 (

Inch

)

52100001Cylindrical

ShankSteel

PFB-R0375SS0375-S600 0.375 0.1875 6 1.688 4.5 2 0.375 4.312 4.46052100002 PFB-R0500SS0500-S550 0.500 0.250 5.5 2.250 4.5 2 0.500 3.250 4.46052100003 PFB-R0625SS0625-S550 0.625 0.3125 5.5 2.500 4 2 0.625 3.000 3.92052100004 PFB-R0750SS0750-S600 0.750 0.375 6 3.000 4 2 0.750 3.000 3.92052100005 PFB-R1000SS1000-S650 1.000 0.500 6.5 3.000 3 2 1.000 3.500 2.88052100011

Cylindrical Shank

Carbide

PFB-R0375SS0375-LL600CS 0.375 0.1875 6.5 2.625 7 2 0.375 3.875 6.96052100012 PFB-R0500SS0500-LL550CS 0.500 0.250 7 3.500 7 2 0.500 3.500 6.96052100013 PFB-R0625SS0625-LL550CS 0.625 0.3125 7.5 3.750 6 2 0.625 3.750 5.92052100014 PFB-R0750SS0750-LL600CS 0.750 0.375 9 4.500 6 2 0.750 4.500 5.92052100015 PFB-R1000SS1000-LL650CS 1.000 0.500 10.5 5.500 5.5 2 1.000 5.000 5.380

List

78014 (

Met

ric)

7801400

Cylindrical ShankSteel

PFB-R080SS08-S120 8 4 120 36 4.5 2 8 84 77801401 PFB-R100SS10-S130 10 5 130 45 4.5 2 10 85 97801402 PFB-R120SS12-S130 12 6 130 54 4.5 2 12 76 117801403 PFB-R160SS16-S140 16 8 140 64 4 2 16 76 147801404 PFB-R200SS20-S160 20 10 160 80 4 2 20 80 187801405 PFB-R250SS25-S160 25 12.5 160 75 3 2 25 85 227801406 PFB-R300SS32-S170 30 15 170 90 3 2 32 80 277801420

Cylindrical Shank

Carbide

PFB-R080SS08-LL140CS 8 4 140 56 7 2 8 84 77801421 PFB-R100SS10-LL150CS 10 5 150 70 7 2 10 80 97801422 PFB-R120SS12-LL160CS 12 6 160 84 7 2 12 76 117801423 PFB-R160SS16-LL200CS 16 8 200 96 6 2 16 104 147801424 PFB-R200SS20-LL240CS 20 10 240 120 6 2 20 120 187801425 PFB-R250SS25-LL260CS 25 12.5 260 137.5 5.5 2 25 122.5 227801426 PFB-R300SS32-LL290CS 30 15 290 165 5.5 2 32 125 27

Packed: 1 pc.

Packed: 1 pc.

The D-STAD is a patent pending diamond coated drill specifically designed to eliminate fiber breakout and delamination issues on both entry and exit of drilled holes. The drill features patent pending triple angle geometry with OSG's patented diamond coating.

Triple Angle Drill

AERO-D-STAD


10,000

1,000

100

10

1Unit Price

OSG’sD-STAD

Competitor’s Carbide Drill

Time Durability Tool Change Cost Total Cost

747％

25％

1,200％

8％55％

Diamond Coated

16

OSG's Triple Angle Drill vs. Competitor's Carbide Tapered Drill

45%Total CostReduction

(Holes) 200 (Holes)

400 (Holes)

600(Holes)

800 (Holes)

Ent

ranc

e

Competitor's PCD twist

Drill

D-STAD

Exi

t

Competitor's PCD twist

Drill

D-STAD

OSG's Triple Angle Drill vs. Competitor's PCD Twist Drill

Initial Cost of D-STAD > Competitor • Total Cost for D-STAD < Competitor

A considerable quality difference at the exit.

Tool Life of D-STAD > Competitor's Twist Drill

w Patented triple angle geometry to reduce push-out exit delamination

w Straight-fluted to eliminate the pull-up entrance delamination


w For non-countersunk holes

w Excellent in CFRP & Al stack applications

Features

Applications 200%

150%

100%

50%

0

Unit Price

OSG’sD-STAD

Competitor’s PCD Twist Drill

Regrind Price Durability Total Cost

76％

200％

175％

43％

24%Total Cost Reduction

Diameter Speed Feed Thickness

ф0.251 V=330SFM f=0.0025IPR .750"

The DAD is a patent pending diamond coated drill specifically designed to eliminate delamination on the exit side only. The drill features our double angle point geometrypaired with our patented diamond coating.

The above graph illustrates the average of three individual trials.

Double Angle Drill

AERO-DAD


Diamond Coated

17

OSG's new drill design for composite materials combines sharpness, low cutting resistance geometries, and our diamond coating to maximize performance.

Tool Dia .2510"

Work Material CFRP

Drilling Speed 200SFM (3,000min-1)

Feed 9IPM (0.003IPR)

Depth of Hole

.675" (.225" Depth Three-layer Stack) (Through)

Coolant Dry

Machine Special Machine for Drilling

Tool Life Delamination

OSG Diamond Coated Drill

Competitor

w Double angle to reduce push- out exit delamination

w High helix for ultra sharp cutting edges


w Best applied for countersunk holes

w Excellent in CFRP & Al stack applications

Features

Applications

400

350

300

250

200

150

100

50

0

OSG Diamond

Coated Drill

Competitor APCD Drill

Competitor CDiamond

Coated Drill

Average of303 Holes

Num

ber

of H

oles

Average of184 Holes

Average of26 Holes

The AERO-LHX is a diamond coated drill specifically for tough to drill laminates. It is designed to complety eliminate uncut fibers and delamination when other drills are unable to properly cut fibers. The drill features unique geometries combined with our patented diamond coating.

When drilling carbon fiber composites, quality of holes can easily be seen from the first few drilled holes. The pictures above show the first hole drilled by a variety of drill designs. As can be seen, the LHX showed the best quality when drilling this particular carbon fiber laminate.

Low Helix Drill

AERO-LHX

Diamond Coated

Entrance Exit

OSGAERO-LHX

Competitor A

Competitor B

Competitor C

Competitor D

Competitor E

Performance HighlightsTotal Cost Performance Analysis

18

w Triple angle geometry to reduce push-out exit delamination

w Low helix providing a sharper cutting edge to help shear tough fibers

w Excels in tough carbon fiber composites

Features

Applications

Tool Dia .2510"

Work Material Carbon Fiber Composite

Drilling Speed 3000 RPM

Feed .001 IPR

Depth of Hole 0.25

Coolant Dry

Machine VMC

Quality Criteria Uncut Fibers

Type N - A diamond coated carbide drill specifically designed for drilling carbon fiber/titanium stack applications. It features a special point geometry with enhanced flute form for optimal chip evacuation to minimize "washout" or "reverse countersink" effect.

Type H - A high helix carbide drill for drilling CFRP/Metal stacks. It features a high helix and special flute form to assist in chip evacuation.

Stack Drilling is a process where both a composite laminate (typically CFRP) is integrated into a match drilliing stack applicaton with a metal (typically aluminum, titanium and or stainless steel). These applications are challenging and unique to each airframe manufacturer. OSG has a positive history and good success in stack drilling applicatons. The following are a few of our solutions.

Type N & Type H

Diamond Coated Stack Drilling

Bright & Diamond Coated

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w Type N - nick geometry to break metal chips to easily managable pieces

w Type H - high helix for sharp cutting edges and easy chip evacuation

w Flute form for enhanced chip room

w Coolant through for cooling and chip evacuation

w Excels in carbon & metal stacks

w Type N - low thrust requirements

w Type H - for general purpose stacks

Features

Applications

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Carbide drill and countersink with internal thread and 60-degree cone seat straight shank style with pin spanner wrench holes or optional wrench flats for slotted type drill wrenches. Application: Spacematic Drill motors with 1” stroke.

Spacematic Drill/Countersink

Carbide drill with 135-degree split point. Used for drilling close tolerance holes in low tensile strength materials. Can also be supplied in taper and screw machine lengths, or special lengths.

NAS 937 Jobbers Length Double Margin Step Drill

Carbide adapter drill manufactured to NAS 907 construction with 135-degree split points. Used for general to medium duty drilling in low tensile strength materials in confined areas.

Threaded Hex Shank Adapter Drill

Carbide drill and countersink with solid shank used in aerospace drivematic drill riveting machines.

Drivematic Drill/Countersink

Designed to produce holes in composite materials without delamination around the hole or fraying the composite materials.

Dagger Drill

Carbide drill and countersink with 135-degree split point. External thread and 60-degree cone seat straight shank style with pin spanner wrench holes. Application: Nutplate and motors with nutplate pressure foot attachments.

Nutplate Drill/Countersink

Special Drilling Tools - Made Upon Request

Innovative Hand Drill for a Wide Variety of Tough to Machine Alloys

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• PCD Countersinks - integral pilot, interchangeable pilot and countersink with interchangeable PCD blade and pilot. The interchangeable pilot and countersink are both available with controlled fillet radius. Also available with brazed PCD.

• PCD Reamers - available in straight or threaded shank with optional pilot.

• PCD Counterbores - aircraft counterbores both in straight and threaded shank. Available with controlled corner radius.

• PCD Drills - shown here in straight flute, 15-degree helix and 30-degree helix.

Neptune™

Applications: Inconel, titanium alloys, stainless steel & aluminum

Features: Engineered for efficient hand drilling, 3 Flutes, TiAlN Coated

Benefits: Reduction of cycle time by 12.5 percent; increased tool life by 60 times.

PCD Drills & Countersinks

360

300

240

180

120

60

0

Number of Holes

NeptuneTM Drilling Average: 19.3 sec/hole

Inconel 718 Plate, .100” Thickness17~20HRC

OSG NeptuneTM

2 Holes

Drilli

ng T

ime

(sec

)

Competitor 2FL HSS Drill

Customer's Test Result

Tool Life Criteria: Chipping or Breakage

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Special Milling Tools - Made Upon Request

Circular Milling ToolThe circular milling tool excels in hole machining utilizing helical interpolation. This tool can produce excellent quality holes in CF/Ti and CF/AL stack materials with an extremely high level of hole circularity. Chipping and burr formation in both metallic and composite structures are also reduced.

Electroplated Diamond Drill/MillThe electroplated Diamond Drill can be used in various applications ranging from drilling-through and blind holes to side and contour grinding.

Replaceable Tip Reamer

Carbide Tipped Core Drill

Replaceable Tip Reamer & Carbide Tipped Core DrillBoth tools are specially designed for final hole size finishing in composites and stack materials.

Hole Quality Comparison

Hole Produced by Circular Interpolation

CFRP

β-Ti

Stacked Material (CFRP/β-Ti)

A good quality hole

OSG's diamond coating and sharp cutting edges prevent delamination.

Delamination is present around the drilled holes.

A poor quality hole, drilled by a competitor

OSG offers a variety of solutions for making efficient and accurate threads in composites. If you have a threading

application please contact our engineering staff at 1-800-837-2223

for threading options.

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Special Threading Tools - Made Upon Request

Electroplated Thread Mill (Thermosetting Plastics)

Thread Mill & Tap (Thermoplastics)

The Electroplated Thread Mill is for grinding of internal threads and composites.

Tapping and thread milling of composites is uncommon. Some composites are capable of being tapped or thread milled, in such cases, OSG can offer special-made tooling for these applications.

• Use safety cover, safety glasses and safety shoes during operation.• Do not touch cutting edges or chips with bare hands.• Stop cutting when the tool becomes dull.• Stop cutting operation immediately if you hear any strange sounds.• Use correct tools for the operation. Check dimensions to ensure proper selection.• Do not modify tools.

© Copyright 2013 OSG Tap & Die, Inc. All rights reserved. Printed in USA. EDP# 800212CA-V2

OSG TAP & DIE, INC.676 E. Fullerton Avenue • Glendale Heights • IL 60139800.837.2223 • FAX: 800.837.3334 • www.osgtool.com

Composite Tool Selection Guide - OSG Tooling Australia · 2016-02-22 · 2 1. N1 - Reaming is...

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Transcript of Composite Tool Selection Guide - OSG Tooling Australia · 2016-02-22 · 2 1. N1 - Reaming is...