（EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
For the processing of small batches and highly customized parts, drilling and tapping often require different tap combinations. The tap inventory in the factory is increasing, and the tool management is becoming more and more complex. Is it possible to use one tap to complete the processing of different parts, and to meet the requirements of processing quality and improve productivity? （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
The Gorman-Rupp Company approached OSG with such a need and found the answer.
Versatile and Efficient
Founded in 1933, Gorman-Rupp Corporation is a world-renowned manufacturer of pumps and pumping systems. Gorman-Rupp Company manufactures pumps for multiple industries such as municipal, sewage, industrial, mining, construction, petroleum, agriculture, and more. The company’s extensive pump product line includes self-priming centrifugal pumps, standard centrifugal pumps, submersible pumps, refuse pumps, diversion auxiliary pumps, rotary gear pumps and air driven diaphragm pumps.
Founded in 1933, Gorman-Rupp Corporation is a world-renowned manufacturer of pumps and pumping systems. Photo courtesy of Gorman-Rupp Company.
Headquartered in Mansfield, Ohio, USA, Gorman-Rupp has more than 1 million square feet of modern manufacturing and warehousing facilities with 100 employees. Gorman-Rupp’s pumps are generally available in cast iron, bronze, AISI316 cast stainless steel (JIS SCS14A) and ASTM CD4MCu (duplex stainless steel) for resistance to corrosive and abrasive liquids. Gorman-Rupp has state-of-the-art fully automated machining centers that allow high-speed and high-quality machining of pump castings. （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
Because every part produced requires drilling and tapping, Gorman-Rupp has used nearly every type and brand of taps over the years. While Gorman-Rupp produces a wide variety of pumps, there are many commonalities in component applications, allowing the production of “component families” with minor differences in component size, hole locations, materials, and more. Since orders are generally small batches and highly customized, the number of holes to be machined for each component is different, which leads to a large number of repeated tap combinations and stocks in Gorman-Rupp’s tool library, including general-purpose taps produced by different manufacturers. to high-performance products.
Gorman-Rupp’s extensive pump product line includes self-priming centrifugal pumps, standard centrifugal pumps, submersible pumps, refuse pumps, booster pumps, rotary gear pumps and air driven diaphragm pumps. Photo courtesy of Gorman-Rupp.
The large tap inventory created tool management problems for Gorman-Rupp that other factories would encounter. Typically, machine operators will select the first tap they find in the tool library that matches the thread name, but may not be the most ideal or suitable tool choice for the material or machining application. （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
To solve this problem, Gorman-Rupp approached OSG, hoping to consolidate its large selection of taps into a more versatile product that could accommodate all of the materials the company uses in the production of pump casings and various pump components. NC programmer Tym Greenwood, project manager at Gorman-Rupp, presented the goal of not only consolidating tools into one factory, but also improving tapping efficiency and reducing overall unit cost (CPU). It was imperative for Gorman-Rupp to simplify tap selection without sacrificing part quality or CPU.
OSG reviewed a list of taps used by Gorman-Rupp over the past 12 months, familiarized themselves with the parts and manufacturing process, and based on commonly used machining materials, OSG recommended Series A taps.
Features
OSG’s A taps are a versatile line of taps that simplifies tool management and excels in a wide variety of materials and applications. Achieving smooth chip evacuation with helical taps in blind hole machining is a challenge for many manufacturers. To address this issue and improve chip evacuation, OSG’s A-SFT features an unequal lead helical flute design that promotes stable chip evacuation. The helix angle varies from the chip forming tip to the chip evacuation notch. This unique design allows for better chip control, helping to create short, regular chips for easy evacuation from the hole.
A taps are known for their excellent chip evacuation. A tap is a general-purpose product line that can adapt to a variety of processing materials and processing environments, and plays a role in helping manufacturers simplify tool management. （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
To accommodate a wide range of cutting conditions, the A-series features a V-coat of powdered high-speed steel and OSG for excellent wear resistance. In addition, in order to achieve high-speed machining, the A-Tap series features a unique cutting edge design that enhances sharpness. The A tap series excels not only in ordinary steel, but also in difficult-to-machine materials such as stainless steel and mild steel. A-Tap is compatible with all types of machining equipment – from manual machines to new advanced machining centers. Type A taps are available in both helical flutes and inclination angles. They can effectively tap almost any material and are one of the most versatile high-performance taps on the market.
The unique characteristics of the A tap make it an excellent choice for Gorman-Rupp for tap integration projects. Gorman-Rupp uses A taps for testing on a variety of processing equipment, materials and applications.
In machining applications of AISI 316 cast stainless steel (JIS SCS14A), testing was performed on a Mazak 630 horizontal machining center using OSG’s 38-16 UNC modified bottom A-SFT spiral flute tap (EDP# 1650511608). The drill size is 0.323″ (blind) and the tap length is 1″. A water-soluble coolant is used during processing. Annual production of cast stainless steel housing parts is estimated at 25,000 pieces. Competitor helical flute taps and OSG’s A-SFT were used at 200rpm spindle speed, 19.63sfm cutting speed, 0.0625ipr and 12.5ipm feed rates. The machining cycle is 9.6 seconds. The competitor’s tool life is 250 pieces, while OSG’s A-SFT is capable of 300 pieces. A-SFT’s knives are also about $8.50 less than the competition’s. Taking into account tool cost, machine cost, tool change time and other factors, the total CPU is 8% lower compared to competitor tools. （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
In ductile iron machining applications, testing was performed on a Mazak 630 horizontal machining center using OSG’s 12-13 UNC modified bottom A-SFT spiral flute tap (EDP# 1650512708). The drill size is 0.437″ (blind) and the tap length is 1.25″. A water-soluble coolant is used during processing. The annual production of this cast iron housing part is estimated at 25,000 pieces. The competitor’s helical flute tap has a spindle speed of 350 rpm, a cutting speed of 45.81 sfm, a feed rate of 0.077 ipr and 26.95 ipm. The cycle time is 5.6 seconds and the tool life is 400 pieces.
Using OSG’s A-SFT, the spindle speed was 530 rpm, the cutting speed was 69.38 sfm, the feed rate was 0.077 ipr and 40.81 ipm. The machining cycle is 3.7 seconds and the tool life is 600 pieces. A-SFT’s knives also cost about $12 less than competitors’ knives. By switching to A-SFT, Gorman-Rupp was able to increase tool life by 1.5 times and reduce cycle times by 34%. Taking into account tool cost, machine cost, tool change time and other factors, total CPU is reduced by 38% compared to competitor tools.
The thread treatment of the A tap is excellent. Gorman-Rupp was very pleased with the thread quality of the A taps compared to the previously selected tool. Even the thread quality of grey cast iron is very good. （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves
The reduction in CPU combined with the convenience of one tap style for all materials made Gorman-Rupp see the value in the A-tap series.
Gorman-Rupp CNC programmer and project manager Tym Greenwood said, “Such excellent machining performance, combined with the technical support that OSG has given us, led us to choose OSG as our primary tap supplier.”
According to a series of test results, the cost of all tapping operations at Gorman-Rupp has been reduced by 20% year-on-year. Since then, all of Gorman-Rupp’s standard taps have been converted to A-series taps, which will continue to further drive efficiency and cost reductions in other machining in the machine shop. （EN10204-3.1 、DIN ASTM GOST GB JIS ANSI BS）Approved Manufacturer of titanium valves