Tailored Solution: OSG Custom Carbide Tap Eliminates Chip Evacuation Issues in Automotive Pipe Production

ZF was originally using a carbide tap M14 for the application. However, the company was experiencing great difficulty with irregular chip formation, bird nesting, and elongated chips that cause chipping of the fillets. Furthermore, with cutting chips clogged up in the bottom of the hole unable to be evacuated, issues such as chipping and tool breakage were also a great headache for the company. OSG Sulamericana was an existing tooling supplier for ZF in other applications. When the opportunity arose to compete within this process, OSG entered and won the order with superior results.

Upon a detailed evaluation of the manufacturing process, OSG Sulamericana Sales Technician Bruno Dias proposed a custom carbide tap M14 x 1.5 7HX with AlTiN coating developed specifically for the application. OSG’s custom carbide tap was put into a Doosan MV3016LS vertical machining center, running at a cutting speed of 30 m/min with soluble oil. ZF’s previous tooling choice was able to complete 1,200 pieces. OSG’s custom tool, on the other hand, was able to complete 2,880 pieces, which more than doubled the efficiency. Immediately, ZF was able to obtain an improvement in the threading process, a gain in tool life, as well as setup time.

“We cannot be more pleased with OSG’s service,” said ZF Engineer Guilherme Gonçalves. “Bruno is always present when help is needed. ZF looks for reliable partners to help during times of trouble, and OSG is always there, which contributes to a long-lasting partnership.”

Previously Featured in OSG's digital Shape It magazine.