Nickel Alloy Solutions

Transcription

1 Industry Solutions for Nickel Materials & Hardened Vol 3 Nickel Solutions

2 Nickel Solutions Index Nickel Solutions CONTENTS EXOPRO WHONi 4 Features & Benefits 5 Cutting Data 6 List 5950Ni 8 List 5955Ni 10 Speeds & Feeds EXOPRO WHRNi EXOPRO WHRNi 11 Features & Benefits 12 Cutting Data 13 List 335Ni 14 List 336Ni 15 List 337Ni 16 List 338Ni EXOPRO WHRNi EXOPRO WHONi EXOCARB Thread Mills 17 Features & Benefits 18 Cutting Data 19 List List List Speeds & Feeds EXOPRO UVXNi 2 Nickel Solutions

3 Nickel Solutions Index EXOPRO UVXNi 23 Features, Benefits & Cutting Data 24 List Speeds & Feeds PHOENIX Indexable Tooling OSG PHOENIX 26 Product Offering 27 Cutting Data EXOTAP VC10 Taps 30 Product Offering VSeries Drills 31 Product Offering EXOPRO UVXNi EXOPRO UVXNi EXOTAP VC10 Nickel Solutions 3

4 Features & Benefits WHONi With more demand to machine nickelbased alloys, OSG has developed the EXOPRO WHONi 3D & 5D carbide drill series. A total solution for drilling nickelbased heatresistant alloys. Sharp Cutting Edge Suppresses Heat Generation The EXOPRO WHONi 3D & 5D Carbide Drills are engineered with sharper cutting edges for drilling nickelbased alloys. The sharp cutting edges are designed to suppress the generation of heat during machining and promotes the stable creation of cutting chips. High Rigidity A Low Helix Angle Results in High Precision Drilling A low helix angle has been used for the flutes to attain high tool rigidity and to make the machining of high precision holes possible. Great Chip Evacuation For Stable Drilling The WHONi 3D & 5D Carbide Drills are able to produce small cutting chips to enable troublefree chip evacuation and stable drilling. EXOPRO WHONi Competitor Excellent Wear Resistance WXS Coating Provides Long and Stable Tool Life The incredible high hardness and heat resistance of OSG s WXS coating, coupled with internallyfed coolant, ensures long, stable tool life. 4 Nickel Solutions

5 WHONi Cutting Data 1.5 Times Longer Tool Life vs. Competitors Inconel 718 The highly rigid body and sharp cutting edge are coated with OSG s WXS coating and achieved 40% more life versus the closest competitor. Tool WHONi 3D Competitors Drill Size Ø6mm Inconel 718 (43 HRC) WHONi Number of Holes Holes Wear Cutting Speed 98 SFM (1,592 RPM) Competitor A 280 Holes Wear Feed Rate Depth of Hole 5.63 IPM ( IPR) 18 mm (Blind, No Step) Competitor B 260 Holes Chipping Coolant Water Soluble (Internal) Competitor C 80 Holes Wear Machine Vertical Machining Center Competitor D 33 Holes Chipping Wear after drilling 440 holes. EXOPRO WHONi Competitor A Suppression of Hole Enlargement Inconel 718 With a highly rigid flute form, the WHONi is able to suppress the enlargement of holes of every size in a stable manner. This allows these tools to be used for machining precision holes. Tool WHONi 5D Competitor Hole expansion while drilling 0 to 200 holes Drill Size Cutting Speed Feed Rate Depth of Hole ØVar Inconel 718 (43 HRC) 98 SFM 1.5% D = IPR 3D (Blind) Hole enlargement (Inch) Coolant Machine Water Soluble (Internal) Vertical Machining Center Entrance Middle Exit Entrance Middle Exit Entrance Middle Exit Entrance Middle Exit EXOPRO WHONi 5D Competitor Nickel Solutions 5

6 WHONi Drills Designed for Nickel s List 5950Ni WHO553D, CoolantThrough R Thinning 140 ØD FL L Ød SPEED FEED P10 CARBIDE WXS 1220 Cutting Diameter Tolerance (h8) Size mm inch D=3 +0 / / <D 6 +0 / / <D / / <D / / EDP Number Diameter Flute Overall Shank Diameter Fractional Size Wire Gage Letter Size mm Inch FL L d / / / / / / / / / / / / Packed: 1 pc. Available WXS Coating Only Nickel Solutions

7 WHONi Drills Designed for Nickel s List 5950Ni (Continued) WHO553D, CoolantThrough SPEED FEED P10 CARBIDE WXS 1220 EDP Number Diameter Flute Overall Shank Diameter Fractional Size Wire Gage Letter Size mm Inch FL L d / / / / W / / / / / / / / Packed: 1 pc. Available WXS Coating Only List No. 5950Ni P M K N S H Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC good best Nickel Solutions 7

8 WHONi Drills Designed for Nickel s List 5955Ni WHO555D, CoolantThrough R Thinning 140 ØD FL L Ød SPEED FEED P10 CARBIDE WXS 1220 Cutting Diameter Tolerance (h8) Size mm inch D=3 +0 / / <D 6 +0 / / <D / / <D / / EDP Number Diameter Flute Overall Shank Diameter Fractional Size Wire Gage Letter Size mm Inch FL L d / / / / / / / / / / / / Packed: 1 pc. Available WXS Coating Only Nickel Solutions

9 WHONi Drills Designed for Nickel s List 5955Ni (Continued) WHO555D, CoolantThrough SPEED FEED P10 CARBIDE WXS 1220 EDP Number Diameter Flute Overall Shank Diameter Fractional Size Wire Gage Letter Size mm Inch FL L d / / / / W / / / / / / / / Packed: 1 pc. Available WXS Coating Only List No. 5955Ni P M K N S H Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC good best Nickel Solutions 9

10 Speeds & Feeds WHONi List 5950NiEXOPRO WHONi: 3D List 5955NiEXOPRO WHONi: 5D General Drilling Operations Work Material Hardness Drilling Speed Drill Dia. Carbon, Mild 1010, 1050, 12L14 Speed RPM 4140, 4130 Cast Iron Ductile Cast Iron NiBase Material, Inconel 3843 HRC SFM SFM SFM SFM SFM Feed IPR Speed RPM Feed IPR Speed RPM mm Inch 3 10, , , , , /8 10, , , , , , , , , , /16 6, , , , , , , , , , /4 5, , , , , , , , , /8 3, , , , , , , , /16 2, , , , , , , , /2 2, , , , Feed IPR Speed RPM Feed IPR Speed RPM Feed IPR General Drilling Operations Work Material Special, Hardened Hardness 3540 HRC 4045 HRC 4556 HRC Drilling Speed SFM SFM SFM Drill Dia. Speed Feed Speed Feed Speed Feed mm Inch RPM IPR RPM IPR RPM IPR 3 4, , , /8 4, , , , , , /16 2, , , , , , /4 2, , , , , , /8 1, , , , /16 1, , , , /2 1, , Nickel Solutions

11 WHRNi Features & Benefits Common Issues Common Issues when Tapping NickelBased s Short Tool Life Tap Breaking Off Inside Workpiece Sudden Tool Wear Chipping of Cutting Edge High Probability of Breakage Edge chipping and wear at the chamfer. OSG Solution: New Design OSG s Newly Designed Point Flute Prevents Chipping The newly designed point flute improves cutting edge rigidity to prevent edge chipping and makes it effective even in blind holes. OSG Solution: HR Coating OSG s HR Coating Improves Wear Resistance This chart illustrates the wear resistance comparison among OSG s HR coating, OSG s V coating and a competitor TiCN coating. In this example, the average tapping speed was 7 SFM. By adopting OSG s HR coating, the tapping speed can be accelerated 1.4 times versus OSG s V coating and the competitor s! Tool WHRNi HR Coating WHRNi V Coating Competitor Margin Wear After 12 Holes Thread Size 3/816 UNC Thread 0.750" Material Drill Depth Cutting Speed Coolant Machine Inconel 718 (43 HRC) Ø0.319" x 1.38" (Blind) 7 SFM (71 RPM) NonWater Soluble Vertical Machining Center HR Coating V Coating Number of Holes WHRNi (HR Coating) 20 Holes WHRNi (V Coating) 15 Holes Competitor A 4 Holes Nickel Solutions 11

12 Cutting Data WHRNi 8 Times the Tool Life Inconel 718 Under identical conditions, the WHRNi tap achieved 8 times the tool life versus the competitor s tap in 718 Inconel (43 HRC). Tool WHRNi Competitor Thread Size 1/428 UNJF Inconel 718 (43 HRC) WHRNi Number of Holes Holes Hole Size Ø0.217" x 0.866" (Blind) Competitor 14 Holes Thread 0.500" (2D) Tapping Speed 6.56 SFM (100 RPM) Coolant NonWater Soluble Machine Vertical Machining Center Stable Long Tool Life Inconel 718 Not only did the WHRNi tap achieve substantially longer tool life than the competition in 718 Inconel (43 HRC), but it also achieved more consistent tool life. Tool WHRNi Competitors Thread Size M4 x 0.7 Inconel 718 (43 HRC) WHRNi Number of Holes Holes 133 Holes Hole Size Thread Ø3.3 x 9.5mm (Through) 9.5mm (2.4D) Competitor A (Steam Oxide) 8 Holes 47 Holes Tapping Speed 9.84 SFM (2,356 RPM) Competitor B (AlCrN) 8 Holes 12 Holes Coolant Machine NonWater Soluble Vertical Machining Center Competitor C (TiCN) 4 Holes 3 Holes Tap No. 1 Tap No Holes 120 Holes 60 Holes 120 Holes WHRNi 12 Nickel Solutions

13 WHRNi Taps Designed for Nickel s List 335Ni WHRNiSFT, DIN Overall, Modified Bottom (2.5P3P) VC10 HR 11 d k Lc Ln L lk Tap Size 2 56 UNC 4 40 UNC 6 32 UNC 8 32 UNC UNC UNF 1/4 20 UNC 1/4 28 UNF 5/16 18 UNC 5/16 24 UNF 3/8 16 UNC 3/8 24 UNF 7/16 14 UNC 7/16 20 UNF 1/2 13 UNC 1/2 20 UNF 9/16 18 UNF 5/8 11 UNC 5/8 18 UNF 3/4 10 UNC 3/4 16 UNF 7/8 9 UNC 7/8 14 UNF 1 8 UNC 1 12 UNF Packed: 1 pc. Available HR coating only. Thread Limit No. of Flutes EDP Number Modified Bottom (2.5P3P) DIN Overall Thread Neck Shank Dia. Square Width Square HR L Lc Ln d k lk H H H H H H P M K N S H List No. Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC 335Ni SFM good best Nickel Solutions 13

14 WHRNi Taps Designed for Nickel s List 336Ni WHRNiSFT, DIN Overall, Modified Bottom (2.5P3P) VC10 HR 11 d k Lc Ln L lk Tap Size Thread Limit No. of Flutes EDP Number Modified Bottom (2.5P3P) DIN Overall Thread Neck Shank Dia. Square Width HR L Lc Ln d k lk M2.5 x D M3 x M4 x D4 6.4 M5 x M6 x M6 x D5 M8 x M8 x M10 x 1.5 D M10 x 1.25 D M12 x D M12 x M14 x 2.0 D M14 x 1.5 D M16 x 2.0 D M16 x 1.5 D M18 x 2.5 D M18 x 1.5 D M20 x 2.5 D M20 x 1.5 D M22 x 2.5 D M22 x 1.5 D M24 x 3.0 D M24 x 1.5 D Packed: 1 pc. Available HR coating only. Square P M K N S H List No. Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC 336Ni SFM Nickel Solutions good best

15 WHRNi Taps Designed for Nickel s List 337Ni WHRNiPOT, DIN Overall, Plug (5P) VC10 HR d k Lc Ln L lk EDP Number DIN Tap Size Thread No. of Overall Thread Limit Flutes Neck Shank Dia. Square Width Square Plug (5P) HR L Lc Ln d k lk 2 56 UNC H UNC UNF H UNC UNC H H UNC H UNF /4 20 UNC /4 28 UNF H /16 18 UNC /16 24 UNF /8 16 UNC /8 24 UNF /16 14 UNC /16 20 UNF /2 13 UNC /2 20 UNF /16 18 UNF /8 11 UNC /8 18 UNF /4 10 UNC /4 16 UNF /8 9 UNC /8 14 UNF UNC UNF Packed: 1 pc. Available HR coating only. P M K N S H List No. Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC 337Ni SFM good best Nickel Solutions 15

16 WHRNi Taps Designed for Nickel s List 338Ni WHRNiPOT, DIN Overall, Plug (5P) VC10 HR d k Lc Ln L lk EDP Number DIN Tap Size Thread No. of Overall Thread Limit Flutes Neck Shank Dia. Square Width Square Plug (5P) HR L Lc Ln d k lk M2.5 x D M3 x M4 x D4 6.4 M5 x M6 x M6 x D5 M8 x M8 x M10 x 1.5 D M10 x 1.25 D M12 x D M12 x M14 x 2.0 D M14 x 1.5 D M16 x 2.0 D M16 x 1.5 D M18 x 2.5 D M18 x 1.5 D M20 x 2.5 D M20 x 1.5 D M22 x 2.5 D M22 x 1.5 D M24 x 3.0 D M24 x 1.5 D Packed: 1 pc. Available HR coating only. P M K N S H List No. Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC 338Ni SFM Nickel Solutions good best

17 EXOCARB Thread Mill Features & Benefits Common Issues Common Issues when Threading NickelBased s Diversification of s Due to the highhardness materials exceeding 50HRC, heatresistant steels and even brittle materials, small diameter internal threads are becoming increasingly difficult to machine. Machining Equipment Constraints Along with the need for ultrahigh speed and high precision operations, small machining centers without reverse function (tap cycles) have emerged. Coolant Constraints Standard taps have difficulty machining nickelbased alloys with watersoluble coolant. OSG Solution 1: Advanced Coatings OSG s EXO, WXS, & SS Coatings OSG s EXO, WXS, and SS coatings provide extreme temperature and wear resistance. OSG Solution 2: Premium Substrate Premium Carbide Substrate OSG s Carbide Substrate provides superior wear resistance and long tool life at high cutting speeds. OSG Solution 3: Optimized Design Optimized Flute Geometry & Thread Form OSG s specially designed helical flute geometry reduces cutting forces, while the thread form minimizes cutting load on both the machine and tool. Nickel Solutions 17

18 EXOCARB Thread Mill Cutting Data Machining Small Diameter Internal Threads Inconel 718 Compared to taps, thread mills have fewer cutting condition limitations. There is no concern with chip management or coolant lubricity, and stable threading is possible. In this example, we were able to improve the yield rate of small diameter internal threads in a high value workpiece. More durability improvements and cost reductions can be expected by adjusting the feed rate and number of passes and changing the cutting fluid. Tool Tool Size EXOCARB Thread Mill 3.2 x 2.4 U32 Cutting Speed Passes Tool life holes Cutting Speed Feed Internal Thread Inconel 718 (43 HRC) 130 SFM (3,980 RPM) 4.72 IPM (0.001 ipt) No UNF 195 SFM (5,970 RPM) 7.07 IPM (0.001 ipt) 130 SFM Holes 60 Holes Drill Hole Size Ø0.161" x (Blind) 195 SFM Tapping Machining Method 0.354" (1.9D) Down Cut, 2/4 Passes 2 40 Holes Coolant Water Soluble Machine Vertical Machining Center Double the Tool Life at Any Cutting Speed Inconel 718 At various cutting speeds under 165 SFM, better durability is achieved. The EXOCARB Thread Mill achieves 2 times the tool life versus the competitor, regardless of the cutting speed. Tool EXOCARB Thread Mill Tool Size 4.55 x 10.8 U20 Inconel 718 (43 HRC) Internal Thread 1/420 UNC Tapping 0.354" Feed Per Tooth ipt Coolant Water Soluble (10%) Machine Horizontal Machining Center Number of Holes Holes Cutting Speed & Tool Life EXOCARB Thread Mill Competitor Cutting Speed SFM Nickel Solutions

19 EXOCARB Thread Mill Ideal for, Exotics and Difficult to Machine Materials List OTSFTPNGT & WXPNC, Regular & Long, Helical Flute SPEED FEED P21 CARBIDE SHANK EXO 1130 h6 Type 1 Type 2 D d D d Lc L1 L Lc L Size Threads Per Inch Cutter Diameter Overall of Cut Neck Shank Diameter No. of Flutes Type EDP Number D L Lc L1 d M M M M M M M M Packed: 1 pc. Available EXO coating only. For internal threads only. For more information on thread mill applications, including ThreadPro software, visit: List No P M K N S H Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC good best Nickel Solutions 19

20 EXOCARB Thread Mill Ideal for, Exotics and Difficult to Machine Materials List WHVMPNC, Miniature, Helical Flute SPEED FEED P22 CARBIDE SHANK SS WXS 11 h6 Type 6 (Lc=3 Threads) ØD Type 5 (Lc=1 Thread) ØD Lc L1 L Ød Lc L1 L Ød Size Threads Per Inch Cutter Diameter Overall of Cut Neck Shank Diameter No. of Flutes Type EDP Number D L Lc L1 d SS WXS / , , , 5, / , Packed: 1 pc. Available in Super Smooth or WXS coatings as shown above. For internal threads only. List WHVMPNC, Miniature, Helical Flute SPEED FEED P22 CARBIDE SHANK SS WXS 11 h6 Type 6 (Lc=3 Threads) ØD Type 5 (Lc=1 Thread) ØD Lc L1 L Ød Lc L1 L Ød Size Threads Per Inch Cutter Diameter Overall of Cut Neck Shank Diameter No. of Flutes Type EDP Number D L Lc L1 d SS WXS M M M M M1.7, M M M2.5, M M M M Packed: 1 pc. Available in Super Smooth or WXS coatings as shown above. For internal threads only. Chart applies to all list numbers above For more information on thread mill applications, including ThreadPro software, visit: P M K N S H Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC good best 20 Nickel Solutions

21 List EXOCARB Thread Mill EXOCARB Thread Mill Speeds & Feeds SFM Feed Rate (Inch/Tooth) No. of Passes Low Carbon Steel Medium Carbon Steel High Carbon Steel Steel Heat Treated Steel (2834HRC) Heat Treated Steel (3440HRC) Heat Treated Steel (4050HRC) Stainless Steel (SUS3**,SUS2**) Stainless Steel (SUS405,410L,430) Stainless Steel (155, 174PH) Cast Iron Cast Iron Ductile Cast Iron Ductile Cast Iron Aluminum Aluminum Casting Si [12]% Aluminum Casting Si [1216]% Aluminum Casting with Si [1620]% Aluminum Casting with Si [2025]% Copper,Copper Casting Brass, Brass Casting Bronze,Bronze Casting (C6***,PB,PBC) Magnesium Casting Zinc Casting Titanium (Ti6AI4V) High Heat Resistance (Inconel) High Heat Resistance (Inconel >40HRC) Thermoplastic Cobalt/Chrome (Stellite) For chip loads, the smaller cutter diameters use a smaller chip load per tooth within a given range. Larger cutter diameters use the larger chip load per tooth within the given range. For programming help or other information, please contact our Engineering Department at Nickel Solutions 21

22 EXOCARB Thread Mill Speeds & Feeds List 41200/41300 EXOCARB Thread Mill Mini SFM Thread Sizes Under #2/M2 Feed Rate (Inch/Tooth) No. of Passes SFM Thread Sizes #2/M2 & Larger Feed Rate (Inch/Tooth) Low Carbon Steel Medium Carbon Steel High Carbon Steel Steel Heat Treated Steel (2834HRC) Heat Treated Steel (3440HRC) Heat Treated Steel (4050HRC) Stainless Steel (SUS3**,SUS2**) Stainless Steel (SUS405,410L,430) Stainless Steel (155, 174PH) Cast Iron Cast Iron Ductile Cast Iron Ductile Cast Iron Aluminum Aluminum Casting Copper,Copper Casting Brass, Brass Casting Bronze,Bronze Casting Magnesium Casting Zinc Casting Titanium (Ti6AI4V) High Heat Resistance (Inconel) High Heat Resistance (Inconel >40HRC) Thermoplastic Cobalt/Chrome (Stellite) For chip loads, the smaller cutter diameters use a smaller chip load per tooth within a given range. Larger cutter diameters use the larger chip load per tooth within the given range. For programming help or other information, please contact our Engineering Department at No. of Passes 22 Nickel Solutions

23 UVXNi Features & Benefits Corner Protection Radius with Variable negative rake angle for strong cutting corners. Variable Helix/Variable Index Vibration absorbtion enables stable machining. Proprietary Cutting Edge Geometry Reduction of cutting heat and forces. Unique Flute Form For excellent chip shape and evacuation. Side Milling in 718 Inconel Inconel 718 Stable performance in Nickel s can be achieved with UVXNi s unique cutting geometry and flute design. Tool UVXNi Competitors Tool Diameter Speed Feed 1/2" x 11/4" x 31/2" 0.030CR Inconel 718 (45 HRC) 764 RPM (100 SFM) 6.02 IPM ( IPT) Depth of Cut Aa: 0.250" / Ar: 0.150" Coolant Water Soluble (External) Amount of Wear (Inch) WHRNi Competitor A Competitor B Competitor C Tool Wear After Milling 39 Inches: UVXNi (Mild wear, no chipping) Comp. A (Severe wear, chipping) Comp. B (Heavy wear) Comp. C (Heavy wear) Nickel Solutions 23

24 UVXNi Designed for Nickel Based s List Flute, Multiple s, Corner Radius SPEED FEED P25 CARBIDE EXO Milling Diameter Tolerance 1/4 D 1 +0/0.0015" Var. D d R Lc L EDP Number EDP Number w/ Weldon Flat Mill Diameter Corner Radius OAL of Cut Shank Diameter D R L Lc d / /2 5/8 1/ / /2 5/8 1/ / /2 5/8 1/ / /2 3/4 5/ / /2 3/4 5/ / /2 3/4 5/ / /2 7/8 3/ / /2 7/8 3/ / /2 7/8 3/ / /2 5/8 1/ / / / / / /2 11/4 1/ / /2 11/4 1/ / /2 11/4 1/ / /2 11/4 1/ / /2 11/4 1/ / /2 11/4 5/ / /2 11/4 5/ / /2 11/4 5/ / /2 11/4 5/ / /2 3/ / /2 3/ / /2 3/ / /2 3/ / / / /2 1 Packed: 1 pc. Available EXO coating only. Weldon Flat 3/8" and above. List No P M K N S H Carbon Stainless Aluminum Nickel Die Cast Titanium Hardened Low Med. High Iron PH Casting Inconel 6Al4V ~ (30 HRC) HRC HRC 4550 HRC 5070 HRC good best 24 Nickel Solutions

25 UVXNi Speeds & Feeds List 2055 EXOPRO UVXNi: 5 Flute, Corner Radius Side Milling Hardness Cutting Speed High Temp. s Inconel Hastelloy SFM Depth of Cut aa= 0.5D ar= 0.3D Mill Dia. Speed RPM Feed in/min 1/4 2, /16 1, /8 1, /2 1, / / Use a rigid and precise machine and holder. 2. When chattering occurs, reduce the speed and feed simultaneously. 3. Use a suitable cutting fluid with high smoke retardant. Slotting Hardness Cutting Speed High Temp. s Inconel Hastelloy SFM Depth of Cut aa= 0.5D Mill Dia. Speed RPM Feed in/min 1/4 1, /16 1, / / / / Use a rigid and precise machine and holder. 2. When chattering occurs, reduce the speed and feed simultaneously. 3. Use a suitable cutting fluid with high smoke retardant. Nickel Solutions 25

26 OSG PHOENIX Indexable Tooling Product Offering OSG PHOENIX Product Lineup Drilling OSG PHOENIX PXD Exchangeable head drill series for efficient, precise hole processing. OSG PHOENIX PHP High performance 3D indexable drill. OSG PHOENIX PD Indexable drill series for efficient, stable hole processing. Milling OSG PHOENIX PAS 45 indexable facemills with 2sided square insert. OSG PHOENIX PAO 45 indexable facemills with 2sided octagon insert. OSG PHOENIX PSE Multifunctional 90 indexable end mills and facemills. OSG PHOENIX PSEL 90 indexable roughing end mills and facemills. OSG PHOENIX PSF 90 indexable shoulder end mills and facemills. OSG PHOENIX PSFL 90 indexable roughing end mills & facemills. OSG PHOENIX PSTW 90 indexable shoulder facemills with 2sided triangle insert. OSG PHOENIX PRC Button insert end mills and facemills for contour milling applications. OSG PHOENIX PHC High feed end mills and facemills for maximum metal removal rates in a variety of applications. OSG PHOENIX PDR Deep feed radius end mills and facemills for deeper depths of cut versus conventional high feed cutters. OSG PHOENIX PFB High precision indexable finish ballnose end mills for superior surface finish and tool life. OSG PHOENIX PFR High precision indexable finish radius end mills for superior surface finish and tool life. OSG PHOENIX SF Modular indexable end mills for a variety of applications. OSG PHOENIX PXM Exchangeable head end mill series for superior surface finish and precision in a variety of applications. 26 Nickel Solutions

27 OSG PHOENIX PRC Radius Cutter Inconel 718 (45 HRC) OSG PHOENIX Indexable Tooling Cutting Data The competitor tool chipped severely after milling 6.5 feet with damage extending to other corners, and made the tool unusable. In contrast, the PRC was able to mill 32.8 feet and resulted in considerably longer tool life. Tool PRC12R050M225 Competitor Insert (grade) RPHT1204MOENSM (XC5035) Coated Carbide Chip Inconel 718 (45 HRC) Cutting Speed 131 SFM (255 RPM) 196 SFM (382 RPM) Feed IPM (0.008 in/t) IPM (0.005 in/t) Depth of Cut Aa: 0.020" / Ar: 1.181" Coolant Machine Water Soluble Horizontal Machining Center Durability 32.8' 6.5' PRC Photo of Insert After Milling 2m Competitor OSG PHOENIX PSE 90 Shoulder Cutter Inconel 718 (45HRC) OSG PHOENIX PSE was able to mill at conditions that were 50% higher than those for conventional tools. It provided double the durability, wore normally and provided longer tool life. Tool PSE11R032SS325S Competitor Insert (grade) ZDKT11T308ERSM (XC5040) Coated Carbide Chip Photo of Tool After Milling 4.9' PSE Competitor Inconel 718 (45 HRC) Cutting Speed 98 SFM (298 RPM) 82 SFM (248 RPM) Feed 4.72 IPM (0.003 in/t) 3.15 IPM (0.003 in/t) Depth of Cut Aa: 0.040" / Ar: 0.787" Coolant Machine Water Soluble Vertical Machining Center Nickel Solutions 27

28 OSG PHOENIX Indexable Tooling Cutting Data OSG PHOENIX PHC High Feed Radius Cutter 630 Stainless Steel A blade was roughmilled under the same conditions for comparison. The PHC provided 1.75 times the durability with more stable milling and with inserts exhibiting normal wear. Tool PHC09R032SS323S Competitor Insert (grade) SDMT09T308ERSM (XC5040) Coated Carbide Chip Cutting Speed Feed 630 Stainless Steel 262 SFM (796 RPM) 31.5 IPM (0.013 in/t) Depth of Cut Aa: 0.020" / Ar: 1.260" Coolant Water Soluble PHC Competitor Machine Vertical Machining Center Completed Parts PHC Competitor OSG PHOENIX PSF 90 Shoulder Cutter Duplex Stainless Steel The competitor tool chipped early on, however, the PHOENIX PSF s stable milling resulted in 5 times the tool life! Tool PSF09R025SS253S Competitor Insert (grade) Cutting Speed SDKT09T308SRGL (XC5040) Duplex Stainless Steel 262 SFM (800 RPM) Coated Carbide Chip PSF Competitor Milling (in) Still Milling! Feed IPM (0.004 in/t) Depth of Cut Aa: 0.079" / Ar: 0.591" Coolant Machine Water Soluble Vertical Machining Center 28 Nickel Solutions

29 OSG PHOENIX PFB Finishing Ball End Mill Heat Resistant Steel (SUH600) OSG PHOENIX Indexable Tooling Cutting Data The OSG PHOENIX PFB demonstrated exceptional wear resistance when machining SUH600 heatresistant steel. Tool Insert (grade) Workpiece Overall Cutting Speed PFBR200SS20S160 Competitor PFB200SP (XP3320) Blade Sample Model SUH600 Steel in 308 SFM (1,500 RPM) Time 70 minutes 140 minutes Milling 4,000 in 8,000 in PFB Wear Amount (in) Feed IPM (0.026 in/t) Depth of Cut Aa: 0.008" / Ar: 0.039" Competitor Coolant Machine Water Soluble Vertical Machining Center Wear Amount (in) OSG PHOENIX PAO 45 Face Milling Cutter Inconel 718 In Inconel 718, the PHOENIX PAO demonstrated excellent wear resistance and achieved four times the durability versus the competitor. Tool PAO06R125M Competitor After 2 meters of milling Insert (grade) OZKU060508SRGM (XC5040) Coated Carbide Chip Inconel 718 Cutting Speed Feed 131 SFM (100 RPM) 4.72 IPM (0.004 in/t) Depth of Cut Aa: 0.059" / Ar: 1.968" Coolant Machine Water Soluble Vertical Machining Center Milling (in) PAO Competitor Nickel Solutions 29

30 EXOTAP VC10 Taps Product Offering V Coating for increased hardness, lubricity & wear resistance. CoolantThrough for smooth chip evacuation. Premium Powdered Metal VC10 Substrate for increased hardness and longer tool life. DIN Overall for longer reach. EXOTAP VC10 Lineup Designed to Excel in Difficult to Machine Materials The EXOTAP VC10 taps feature unique geometries to excel in Nickel or other difficult to machine materials. Series EXOTAP VC10 Ti EXOTAP VC10 Ti Oil EXOTAP VC10 Ni EXOTAP VC10 EXOTAP VC10 Oil List Number Style Size Range Features 313Ti No. 2 1 Spiral Flute 345Ti M2.5 M12 VC10 Powdered Metal Tap, 312Ti No. 2 1 SteamOxide or Vcoated Spiral Point Ideal for Tis & 344Ti M3 M12 Difficult to Machine 315Ti STI, Spiral Fluted No. 2 ½ Materials 314Ti STI, Spiral Pointed No. 2 ½ 317Ti Spiral Flute, CoolantThrough, 1/4" 1" CoollantThrough VC10 DIN OAL M8 M24 Powdered Metal Tap, Steam 348Ti Oxide or Vcoated, Ideal for 316Ti Spiral Point, CoolantThrough, DIN OAL M8 M24 Materials 1/4" 1" Tis & Difficult to Machine 347Ti 313Ni No. 2 1 Spiral Flute 345Ni M2.5 M12 VC10 Powdered Metal Tap, 312Ni No. 2 1 Vcoated Spiral Point 344Ni M2.5 M12 Ideal for Nis & Difficult to Machine Materials 315Ni STI, Spiral Fluted No. 2 ½ 314Ni STI, Spiral Pointed No. 2 ½ 313 No. 2 ¾ Spiral Flute 345 M3 M No. 2 ¾ Spiral Point VC10 Powdered Metal Tap, 344 M3 M12 SteamOxide or Vcoated 315 No. 2 1 Ideal for Difficult to STI, Spiral Fluted Machine Materials 345STI M2 M No. 2 1 STI, Spiral Pointed 344STI M2 M Spiral Flute, CoolantThrough, 5/16" 1" CoolantThrough VC10 DIN OAL M8 M24 Powdered Metal Tap, 351 SteamOxide or Vcoated, 316 Spiral Point, CoolantThrough, DIN OAL M6 M24 1/4" 1" Ideal for Difficult to Machine 350 Materials P M S H Stainless Nickel PH Inconel Titanium 6Al4V (30 HRC) Hardened ~35 HRC 3545 HRC 30 Nickel Solutions

31 VSeries Drills Product Offering VSeries Drilling Lineup VPHGDS & VPHGDR Vcoated, XPM powdered metal drills, are ideal for Nickel s and other difficult to machine materials. P M S H Series List Number Style Size Range Die Stainless Nickel Titanium Hardened PH Inconel 6Al4V (30 HRC) ~35 HRC 3545 HRC 4550 HRC VPHGDS 1900 Stub #73 3/4 ( mm) VPHGDR 1950 Jobbers #47 11/16 (1.99mm 17.46mm) Performance of VPHGDS Inconel 718 Made of highquality powdered HSS, the highly rigid body combined with a sharp cutting edge is able to surpass the competitor s durability when machining Inconel 718. In a general oilbased coolant environment, the VPHGDS is also able to provide more stable machining. Tool VPHGDS Competitor Tool Size Ø5.9 Inconel 718 (43 HRC) VPHGDS Number of Holes Drilling Speed Feed Depth of Hole Coolant Machine 20 SFM (329 RPM) IPR 12mm (Blind) 3mm Step Water Soluble (External) Vertical Machining Center Competitor VPHGDS Competitor Nickel Solutions 31

32 Safe use of cutting tools Use safety cover, safety glasses and safety shoes during operation. Do not touch cutting edges with bare hands. Do not touch cutting chips with bare hands. Chips will be hot after cutting. Stop cutting when the tool becomes dull. Stop cutting operation immediately if you hear any abnormal cutting sounds. Do not modify tools. Please use appropriate tools for the operation. Check dimensions to ensure proper selection. TEXAS (National Headquarters) 1945 W. Walnut Hill Ln. Irving, TX 75038, USA Toll Free: Fax: ILLINOIS 676 East Fullerton Avenue Glendale Heights, IL 60139, USA Toll Free: Fax: CALIFORNIA 1921 Miraloma Ave. Suite B Placentia, CA 92870, USA Toll Free: Fax: OHIO 3611 Socialville Foster Rd. Ste 102 Mason, OH 45040, USA Phone: Fax: GEORGIA 5324 Highway 85 Ste 100 Forest Park, GA 30297, USA Toll Free: Fax: CANADA 538 King Forest Court Burlington, ON L7P 5C1, Canada Toll Free: Fax: MEXICO Avenida Central No. 186 Col. Nueva Industrial Vallejo Ciudad de Mexico, D.F., Mexico Phone: (52) Fax: (52) Copyright 2018 OSG USA, INC. All rights reserved. Printed in USA. EDP#800257CAV3