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1. N1 - Reaming is Required 2. N2 - Step Feed is Required
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
DIA-BNC
DIA-HBC xDIA-MFR 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 DIA-D-STAD x xDIA-LHX x x x x xDIA-DAD x x 2 x x
Stac
k Type N x 1 x xType H x x x
GoodOKNot Recommended Bestx
GoodOKNot Recommended Bestx
Routers
Drills
The Patented Ultra-Fine Grain Size
OSG Ultra-Fine Diamond Coating
OSG Ultra-Fine Diamond Coating
Competitor Diamond Coating(Industry Standard)
Diamond Delamination (Note: Large Grain Size)
Elimination of Diamond Delamination
Advantage #1
Advantage #2
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.
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
l
Packed: 1 pc. Available Diamond coating only.Type 1: No End Cut, Type 2: Bur End, Type 3: End Mill Cut
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%
EDP NumberMill Dia. Length of Cut OAL Shank Diameter
No. of Flutes Type Stock PriceD l L d
20610116 1/8 1/4 1 1/2 1/8 6 2 ○20611116 1/8 3/8 1 1/2 1/8 6 3 ○20612116 1/8 1/2 1 1/2 1/8 8 3 ○20610216 3/16 3/8 2 3/16 6 2 ○20611216 3/16 9/16 2 3/16 6 3 ○20612216 3/16 3/4 2 3/16 8 3 ○20610316 1/4 1/2 2 1/2 1/4 8 2 ○20611316 1/4 3/4 2 1/2 1/4 10 3 ○20612316 1/4 3/4 2 1/2 1/4 10 2 ○20613316 1/4 1 3 1/4 10 3 ○20614316 1/4 1 3 1/4 10 2 ○20615316 1/4 1 1/4 4 1/4 12 1 ○20610416 5/16 1 2 1/2 5/16 10 3 ○20610516 3/8 3/4 2 1/2 3/8 12 2 ○20611516 3/8 1 1/8 3 3/8 12 3 ○20612516 3/8 1 1/8 3 3/8 12 2 ○20613516 3/8 1 1/2 4 3/8 12 3 ○20614516 3/8 1 1/2 4 3/8 12 2 ○20615516 3/8 2 4 3/8 12 1 ○20610716 1/2 1 3 1/2 14 3 ○20611716 1/2 1 3 1/2 14 2 ○20612716 1/2 2 4 1/2 16 2 ○
EDP NumberMill Dia. Length of Cut OAL Shank Diameter
No. of Flutes Type Stock PriceD l L d
48108001 6 18 68 6 8 2 ●48108002 8 24 74 8 10 2 ●48108003 10 30 80 10 12 2 ●48108004 12 36 86 12 14 2 ●48108011 6 18 68 6 8 3 ●48108012 8 24 74 8 10 3 ●48108013 10 30 80 10 12 3 ●48108014 12 36 86 12 14 3 ●
DIA-BNC
Recommended Cutting ConditionsSide milling Slotting
Speed m/min. 120 240 90 180
Depth of Cut Aa: Up to 1,5D / Ar: Up to 1D Aa: 1D
Dia. Feed mm/min Feed mm/min Feed mm/min Feed mm/min 1/8 500 1.000 250 500 3/16 630 1.300 300 600 1/4 6mm 770 1.600 380 750 5/16 8mm 900 1.800 450 900 3/8 10mm 1.000 2.000 510 1.000 1/2 12mm 1.300 2.600 630 1.300
4
Metric
Inch
The DIA-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
Mill
ing
Leng
th (m
)
DIA-BNC10 mm
Competitor S(Dia. Coated)
Tool Life Comparison
w By utilizing Flute Position Management*, tool life can be increased.
Flute Management
*To change the milling position at the flute
5
Packed: 1 pc. Available Diamond coating only.
Herringbone Router - Diamond Coated
Packed: 1 pc. Available Diamond coating 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 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%
Inch
Metric
Inch
EDP NumberMill Diameter Compression Length Length of Cut OAL Shank Diameter No. of
Flutes Stock PriceD L2 l L d
20660116 1/8 0,125 3/8 1 1/2 1/8 4 ○20660316 1/4 0,250 3/4 2 1/2 1/4 4 ○20660516 3/8 0,375 1 1/8 3 3/8 4 ○20660716 1/2 0,500 1 1/8 3 1/2 4 ○
EDP NumberMill Diameter Compression Length Length of Cut OAL Shank Diameter No. of
Flutes Stock PriceD L2 l L d
48109001 6 7,5 15 65 6 4 ●48109002 8 10 20 70 8 4 ●48109003 10 12,5 25 75 10 4 ●48109004 12 15 30 100 12 4 ●
l
DIA-HBC
Recommended Cutting ConditionsSide Milling Slotting
Speed m/min. 120 240 90 180
Depth of Cut Aa: Up to 1,5D / Ar: Up to 1D Aa: 1D
Dia. Feed mm/min. Feed mm/min. Feed mm/min. Feed mm/min. 1/8 500 1.000 250 500 1/4 6mm 770 1.600 380 750 8 mm 900 1.800 450 900 3/8 10mm 1.000 2.000 510 1.000 1/2 12mm 1.300 2.600 630 1.300
6
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
ToolDIA-HBC Competitor
Herringbone Router - Diamond CoatedMaterial Carbon Fiber CompositeDiameter 12 mm
Number of Flutes 4 6
Milling Method Side Milling
Speed 6000 RPMFeed 600~1.200 mm/min.DOC Aa: 6,35 mm / Ar: 3,17 mm
Coolant DryMachine VMC
The DIA-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 DIA-HBC showed excellent performance and surface finished at high feed rates. The 4-flute herringbone design was able to mill up to 1.200mm/min. without leaving streak marks on the composite.
DIA-HBC
Clean milling at 1.200 mm/min.
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
7
Packed: 1 pc. Available Diamond coating only.
Finishing Router - Diamond Coated
Finishing Router - Diamond Coated
l L
D
Packed: 1 pc. Available Diamond coating 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.
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%
EDP NumberMill Diameter Length of Cut OAL Shank Diameter
No. of Flutes Stock PriceD l L d
26500316 1/4 3/4 2 1/2 1/4 8 ○26501316 1/4 1 3 1/4 8 ○26500616 3/8 1 1/8 3 3/8 12 ○26501516 3/8 1 1/2 3 3/8 12 ○26500716 1/2 1 1/2 4 1/2 14 ○26501716 1/2 2 4 1/2 14 ○
DIA-MFR
Recommended Cutting ConditionsSide Milling
Speed m/min. 120 250
Depth of Cut Aa: Up to 1D / Ar: ≤ 0,2D
Dia. Feed mm/min. Feed mm/min. 1/4 770 3.000 3/8 1.000 3.500 1/2 1.300 5.000
8
Tool OSG Competitor G Electroplated
Material Carbon / CarbonDiameter 8 mm
Milling Method Slotting
Speed 2700 RPM 9795 RPMFeed 1.210 mm/min.DOC Aa: 10 mm
Coolant Dry
OSG Competitor G
Total Tool Life Cost/Inch
Electroplated0
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)
0,025
0,012
0,000
-0,012
-0,025
-0,038
-0,050
-0,060
-0,080
508.000
380.000
250.000
127.000
€ 38,50
€ 31,00
€ 23,10
€ 15,40
€ 7,70
€ 00
OSG Competitor G
Total Tool Life Cost/Inch
Electroplated0
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)
0,025
0,012
0,000
-0,012
-0,025
-0,038
-0,050
-0,060
-0,080
508.000
380.000
250.000
127.000
€ 38,50
€ 31,00
€ 23,10
€ 15,40
€ 7,70
€ 00
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 DIA-REC for roughing
Features
Applications
The DIA-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 DIA-MFR showed the best accuracy versus carbide diamond coated competition as well as electroplated products.
Performance Highlights
w By utilizing Flute Position Management*, tool life can be increased.
Flute Management
*To change the milling position at the flute
9
DG-EBD (Metric)
10
Packed: 1 pc. Available Diamond coating only.
EDP NumberMill Diameter Length of Cut OAL Shank Diameter
Stock PriceD l L d
8553541 4 2 80 4 ●8553561 6 3 80 6 ●8553581 8 4 100 8 ●8553601 10 5 100 10 ●8553621 12 6 130 12 ●
dD
Ll
R
Diamond Coated End Mills
Recommended Cutting Conditions
Depth of Cut Roughing Finishing(mm/min.) (mm/min.) (mm) (mm/min.) (mm/min.) (mm)
R x l x L (mm) Short --- Long Short --- Long ap pf Short --- Long Short --- Long ap pf
R2 X 8 X 80 16~40 20.000 ~ 11.000 3.150 ~ 1.800 0,4 1,2 20.000 ~ 11.000 2.100 ~ 1.200 0,12 0,12R3 X 12 X 80 24~36 20.000 ~ 9.600 4.500 ~ 2.100 0,6 1,8 20.000 ~ 9.600 3.000 ~ 1.400 0,18 0,18
R4 X 20 X 100 32~56 16.000 ~ 7.200 3.900 ~ 1.800 0,8 2,4 16.000 ~ 7.200 2.600 ~ 1.200 0,22 0,22R5 X 20 X 100 40~60 12.500 ~ 5.700 3.000 ~ 1.350 1,0 3,0 12.500 ~ 5.700 2.000 ~ 900 0,26 0,26R6 X 36 X130 48~84 10.500 ~ 4.800 2.550 ~ 1.100 1,2 3,6 10.500 ~ 4.800 1.700 ~ 750 0,30 0,30
PFB (Inch & Metric)
11
Metric
Metric
φD
L
l1 l2
φd
φd2R
Ball End Indexable (PFB)
Steel Shank
EDP No. Body Type Designation
Tool Dia.
(mm)
Tool Rad.(mm)
OAL(mm)
Neck Length(mm)
L/D Ratio
No. of Teeth
Shank Dia.
(mm)
Shank Length(mm)
Neck Dia.
(mm) Stock Price
D R L l1 d l2 d27801400
Cylindrical ShankSteel
PFB-R080SS08-S120 8 4 120 36 4,5 2 8 84 7 ●7801401 PFB-R100SS10-S130 10 5 130 45 4,5 2 10 85 9 ●7801402 PFB-R120SS12-S130 12 6 130 54 4,5 2 12 76 11 ●7801403 PFB-R160SS16-S140 16 8 140 64 4 2 16 76 14 ●7801404 PFB-R200SS20-S160 20 10 160 80 4 2 20 80 18 ●7801405 PFB-R250SS25-S160 25 12,5 160 75 3 2 25 85 22 ●7801406 PFB-R300SS32-S170 30 15 170 90 3 2 32 80 27 ●7801430
Cylindrical Shank
Carbide(short)
PFB-R080SS8-S100CS 8 4 100 20 2,5 2 8 80 7 ●7801431 PFB-R100SS10-S100CS 10 5 100 25 2,5 2 10 75 9 ●7801432 PFB-R120SS12-S110CS 12 6 110 30 2,5 2 12 80 11 ●7801433 PFB-R160SS16-S140CS 16 8 140 40 2,5 2 16 100 14 ●7801434 PFB-R200SS20-S160CS 20 10 160 50 2,5 2 20 100 18 ●7801435 PFB-R250SS25-S160CS 25 12,5 160 62,5 2,5 2 35 97,5 22 ●7801436 PFB-R300SS32-S170CS 30 15 170 75 2,5 2 32 95 27 ●7801420
Cylindrical Shank
Carbide(long)
PFB-R080SS08-LL140CS 8 4 140 56 7 2 8 84 7 ●7801421 PFB-R100SS10-LL150CS 10 5 150 70 7 2 10 80 9 ●7801422 PFB-R120SS12-LL160CS 12 6 160 84 7 2 12 76 11 ●7801423 PFB-R160SS16-LL200CS 16 8 200 96 6 2 16 104 14 ●7801424 PFB-R200SS20-LL240CS 20 10 240 120 6 2 20 120 18 ●7801425 PFB-R250SS25-LL260CS 25 12.5 260 137,5 5,5 2 25 122,5 22 ●7801426 PFB-R300SS32-LL290CS 30 15 290 165 5,5 2 32 125 27 ●
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) Stock Price
D R L l1 d l2 d252100001
Cylindrical ShankSteel
PFB-R0375SS0375-S600 0,375 0.1875 6 1,688 4,5 2 0,375 4,312 4,460 ●52100002 PFB-R0500SS0500-S550 0,500 0.250 5,5 2,250 4.5 2 0,500 3,250 4,460 ●52100003 PFB-R0625SS0625-S550 0,625 0.3125 5,5 2,500 4 2 0,625 3,000 3,920 ●52100004 PFB-R0750SS0750-S600 0,750 0.375 6 3,000 4 2 0,750 3,000 3,920 ●52100005 PFB-R1000SS1000-S650 1,000 0.500 6.5 3,000 3 2 1,000 3,500 2,880 ●52100011
Cylindrical Shank
Carbide
PFB-R0375SS0375-LL600CS 0,375 0,1875 6,5 2,625 7 2 0,375 3,875 6,960 ●52100012 PFB-R0500SS0500-LL550CS 0,500 0,250 7 3,500 7 2 0,500 3,500 6,960 ●52100013 PFB-R0625SS0625-LL550CS 0,625 0,3125 7,5 3,750 6 2 0,625 3,750 5,920 ●52100014 PFB-R0750SS0750-LL600CS 0,750 0,375 9 4,500 6 2 0,750 4,500 5,920 ●52100015 PFB-R1000SS1000-LL650CS 1,000 0,500 10,5 5,500 5,5 2 1,000 5,000 5,380 ●
Packed: 1 pc.
Appearance Designa-tion Spec.
No. ofcut-ting
edges
Insert Size Grade of Coated materialStock Price
D R T H XC4505PFB080-D
Spiral Type (Diamond Coated)
2 8 4 2,4 7 7820020 ●PFB100-D 2 10 5 2,6 8,5 7820021 ●PFB120-D 2 12 6 3 10 7820022 ●PFB160-D 2 16 8 4 12 7820023 ●PFB200-D 2 20 10 5 15 7820024 ●PFB250-D 2 25 12,5 6 18,5 7820025 ●PFB300-D 2 30 15 7 22,5 7820026 ●
Appearance Designa-tion Spec.
No. ofcut-ting
edges
Insert Size Grade of Coated materialStock Price
D R T H XC4505PFB0375-D
Spiral Type (Diamond Coated)
2 0,375 0,1875 2.6 8.5 52101001 ○PFB0500-D 2 0,500 0,250 3 10 52101002 ○PFB0625-D 2 0,625 0,3125 4 12 52101003 ○PFB0750-D 2 0,750 0.375 5 15 52101004 ○PFB1000-D 2 1,000 0.500 6 18,5 52101005 ○
Inch
Inch
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
DIA-D-STAD
Performance Highlights
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
12
Packed: 1 pc. Available Diamond coating only.
EDP NumberMill Diameter Length OAL Shank Diameter
Stock PriceD l L d
48154001 4 30 80 4 ●48154002 6 40 90 6 ●48154003 8 50 100 8 ●48154004 1/4 38 88 1/4 ●
OSG's Triple Angle Drill vs. Competitor's Carbide Tapered Drill
45%Total CostReduction
(Holes) 200 (Holes)
400 (Holes)
600(Holes)
800 (Holes)
Competitor's PCD twist
Drill
D-STAD
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 Excels in carbon and glass composites and honeycombs
w For non-countersunk holes
w Excellent in CFRP & Al stack applications
Features
Applications
Recommended Cutting Conditions
Depth of Cut
Speed m/min. 50 ~ 100 m/minDia RPM F (mm/rev.)4 4.000 ~ 8.000 0,03 ~ 0,056 2.600 ~ 5.300 0,04 ~ 0,078 2.500 ~ 5.000 0,04 ~ 0,08
1/4 2.000 ~ 4.000 0,05 ~ 0,07
Diameter Speed Feed Thickness6 mm 100 m/min. 0,06 mm/rev 20 mm
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
DIA-DAD
Performance Highlights
Diamond Coated
13
EDP NumberMill Diameter Length OAL Shank Diameter
Stock PriceD l L d
48154001 4 30 80 4 ●48154002 6 40 90 6 ●48154003 8 50 100 8 ●48154004 1/4 38 88 1/4 ●
OSG's new drill design for composite materials combines sharpness, low cutting resistance geometries, and our diamond coating to maximize performance.
Tool Dia 6 mm
Work Material CFRP
Drilling Speed 60 m/min.
Feed 0,07 mm/rev.
Depth of Hole
18 mm DepthThree-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 Excels in carbon and glass composites and honeycombs
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
Depth of Cut
Speed m/min. 50 ~ 100 m/minDia RPM F (mm/rev.)4 4.000 ~ 8.000 0,03 ~ 0,056 2.600 ~ 5.300 0,04 ~ 0,078 2.500 ~ 5.000 0,04 ~ 0,08
1/4 2.000 ~ 4.000 0,05 ~ 0,07
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
DIA-LHX
Diamond Coated
Entrance Exit
OSGDIA-LHX
Competitor A
Competitor B
Competitor C
Competitor D
Competitor E
Performance HighlightsTotal Cost Performance Analysis
14
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 6 mm
Work Material Carbon Fiber Composite
Drilling Speed 60 m/min
Feed 0,03 mm/rev.
Depth of Hole 6 mm
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
15
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
16
• 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.
PCD Drills & Countersinks
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.
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 has a variety of options 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.
17
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.
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Tool specifications subject to change without notice
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