Diamond-coated Router Designed primarily for trimming of CFRP, we offer a variety of router styles to accommodate our customers needs including a multi-flute type with nicks for high efficiency, Herringbone flute type for reducing cutting resistance, a surface finish-focused type, and more. Herringbone Cutter High efficient type: Fine-cross-nick router High efficiency type: Coarse-cross-nick router The sharp edges perform slot milling in CFRP without delamination of the side and top surfaces. Cross-flute router Finishing router In GFRP honeycomb material, there are no tiny burrs on the top and bottom surfaces nor peeling off or fraying of the core material. PCD, Electroplated Tools Electroplated Diamond Drill In addition to the PCD end mills and electroplated tools shown in the picture, PCD drills are available on a special order basis. PCD End Mill Circular Interpolation This is a dedicated tool for hole machining using circular interpolation on machining centers or specialized machines for circular milling. On stacked materials such as CFRP/Ti or CFRP/Al, a higher level of hole cylindricity is achieved by eliminating hole expansion, chipping and burr formation in both the metallic and CFRP portions, and hole shrinkage in the CFRP portions. β-ti CFRP Stacked Material (CFRP/β-Ti) 2
EXOCARB -AERO Routers: OSG Diamond Coated Routers for Milling CFRP and other Composites List 2060 Regular Length, Multiple Flutes with End Cut Minimizes Delamination, Rougher Tolerance for milling diameter 0 ~ 0.002 Type 1* Type 2** EDP Number Mill Diameter Length of Cut 20601716 1/2 1 1/2 3 1/2 12 2 352.42 Packed: 1 pc. Available Diamond coating only. *Type 1-2-flute end cut for plunging. **Type 2 - Standard multi-flute router end cut. OAL Shank Diameter No. of Flutes Type List Price (Each) D Lc L d 20600116 1/8 3/4 1 1/2 1/8 8 1 78.41 20601116 1/8 3/4 1 1/2 1/8 8 2 84.49 20600316 1/4 1 2 1/2 1/4 12 1 127.80 20601316 1/4 1 2 1/2 1/4 12 2 134.03 20600516 3/8 1 1/4 2 1/2 3/8 12 1 202.10 20601516 3/8 1 1/4 2 1/2 3/8 12 2 286.89 20600716 1/2 1 1/2 3 1/2 12 1 255.16 List 2065 Regular Length, Multiple Flutes with End Cut Minimizes Delamination, Finisher Tolerance for milling diameter 0 ~ 0.002 D L2 Lc L EDP Number Mill Diameter Packed: 1 pc. Available Diamond coating only. Upshear Length Length of Cut OAL Shank Diameter No. of Flutes List Price (Each) D L2 Lc L d 20650116 1/8 0.135 1/2 1 1/2 1/8 4 77.28 20650316 1/4 0.225 3/4 2 1/2 1/4 6 110.56 20650516 3/8 0.338 1 2 1/2 3/8 6 184.14 20650716 1/2 0.450 1 1/8 3 1/2 6 231.88 Work Material List No. Graphite CFRP GFRP 2060 2065 good best 3
Recent change in materials for aerospace applications Materials used in aerospace applications have been changing dramatically in recent years. Among composite materials, CFRP is becoming especially important. Machining CFRP has its own difficulties including rapid tool wear and delamination. As for metal aerospace components, as the amount of titanium used increases, from 6-4Ti to β-ti, machining becomes more difficult. For many years, OSG has been committed to producing cutting tools for aerospace, in Japan as well as in the USA, Canada, Brazil and Europe. We started engaging in newly developed materials such as CRFP and β-ti since 1990. OSG offers numerous types and styles: PCD tools, electroplated tools, carbide tools with variety of coatings for titanium, DLC coated tools for aluminum alloys, and HSS special order tools. All tools are designed to meet the range of requirements and applications and tested to ensure their superior performance. Specialty Aircraft Tools: Solid Micrograin Carbide Spacematic Drill/Countersink 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. Drivematic Drill/Countersink Carbide drill and countersink with solid shank used in aerospace drivematic drill riveting machines. Carbide Tapered Reamer Our carbide tapered reamers are designed for finishing hole sizes in composite materials. The geometries incorporated into the design of these tools produce excellent results; flaking, tearing, and cracking in laminate materials are minimized. Threaded Hex Shank Adapter 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. NAS 937 Jobbers Length Double Margin Step Drill 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. 4
Specialty Aircraft Tools: Solid Micrograin Carbide Nutplate Drill/Countersink 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. Type 56 Threaded Square Shank Adapter Drill Carbide step adapter drills are manufactured similar to NAS 907 construction with 135 degree split points. Used for drilling hard, tough, high tensile strength materials in confined areas. Dagger Drill This carbide drill is designed to produce holes in composite materials without delamination around the hole or fraying the composite material. Even the Ultra Fine Crystal Diamond Coating can be removed and recoated. PATENTED Ultra Fine Crystal Diamond Coating OSG s new patented diamond coating is made from ultra fine diamond crystals in an innovative new process. It will give a better surface finish and performance and is only available from OSG. Ultra Fine Crystal Diamond Coating Competitor's Diamond Coating 5
Diamond Coated Carbide Drill For outlets and inlets: triple-angle drill PAT.P. Two types of drills are available. One is a drill designed for eliminating delamination around the outlet of the hole (PAT.P.) (lower photo). The other type is for eliminating delamination around both the inlet and outlet of the hole (PAT.P.) (upper photo). On both types, the new flute form reduces and disperses cutting force and produces holes of exceptional quality. For outlets: high helix, double-angle drill PAT.P. A good quality hole A poor quality hole, drilled by a competitor The diamond coating and sharp cutting edges prevent delamination. Delamination is present around the drilled hole. 6
Milling Solutions for CFRP Herringbone Cutter Our new end mill series for CFRP incorporates a herringbone flute design which diverts cutting forces inwards eliminating delamination. In addition our patented diamond coating with it s finer grain structure allows for a sharper cutting edge which in turn helps prolong tool life and produce a superb surface finish. OSG Special geometry diverts cutting forces inwards eliminating delamination Tool Dia 3/8" (ø9.525mm) Work Material Milling Method Milling Speed CFRP Side Milling 314 SFM Milling Length (m) 5 10 15 Feed Coolant 13.71 IPM Dry OSG Diamond Coated Herringbone Cutter Machine Tool Life Vertical Machining Center Resin Welding Competitor Drilling Solutions for CFRP High Helix, Double-angle Drill The drilling of composite materials is becoming more common. Our CFRP drills combination of sharpness, low-resistance design, and outstanding diamond coating offers maximum performance. Customer Data Number of holes (holes) 50 100 150 200 250 300 350 400 OSG Diamond Coated Drill Average 303 Holes OSG Competitor Tool Dia Work Material.2510" (ø6.375mm) CFRP Competitor A PCD Drill Average 184 Holes Drilling Speed 196 SFM Feed Depth of Hole 0.66 IPM 5.7mm Depth Three-layer Stack (Through) Competitor B PCD Drill Average 140 Holes Coolant Machine Tool Life Dry Special Machine for Drilling Delamination Competitor C Diamond Coated Drill Average 26 Holes 7
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. OSG TAP & DIE, INC. 676 E. Fullerton Avenue Glendale Heights, IL 60139 800.837.2223 FAX: 800.837.3334 www.osgtool.com Copyright 2010 OSG Tap & Die, Inc. All rights reserved. Printed in the USA. EDP# 800197CA 3M j-a