Records of achievements

Vehicle components

Crank shaft Material (Joining dimension)::S43C×S43(35)
Application: Engine system parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Too many kinds of forging die
  • Higher forging cost

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Dividing and adaptation to mass production by making the weight section sharable
  • Reduced number of dies in stock by using common forging dies
  • Reduced forging cost
  • Reduced grinding allowance

Engine valve Material (Joining dimension):SUH3×Inconel713C(4~9)
Application: Engine system parts
Pre-friction joining method/Problems

Flash butt welding

  • Frequent occurrences of defective joining
  • Non-destructive inspection process is necessary.

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Abolition of non-destructive inspection process
  • Burrs in the machine can be removed using a press. (Process reduction)
  • Less electric power consumption, reduced number of processes and improvement of yield

Hollow camshaft Material (Joining dimension):Pipes (29 x t5) equivalent to S45C x S45C
Application: Engine system parts
Pre-friction joining method/Problems
Grinding out from solid casting or forging stock

  • Larger gross weight
  • Inferior revolution balance
  • Larger cost due to many machining sections

 
Category
Quality Cost Lightening
Purpose and effects
  • Reduced weight thanks to use of hollow pipes
  • Enhanced revolution balance
  • Optimum material with higher abrasion resistance can be used at the cam section.

Counter gear shaft Material (Joining dimension): S43C to S43C ((77 x t15)
Application: Engine system parts
Pre-friction joining method/Problems
Grinding out from solid forging stock

  • Overall machining is necessary.
  • Heavier gross weight

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Abolition of gear relief machining section (conversion to forging)
  • Weight reduction owing to use of hollow material

Counter gea Material (Joining dimension): S43C to S43C(77×t15)
Application: Engine system parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Overall machining is necessary.

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Reduced forging cost as a result of dividing
  • Enhanced accuracy of forging O.D. (roundness) as a result of dividing
  • Reduced machining allowance as a result of enhanced accuracy of O.D.

Torque converter pump shell Material (Joining dimension)):SHP45×t3(32×t3)
Application: Engine system parts
Pre-friction joining method/Problems

CO2 arc welding

  • Oil leak from un-welded section
  • Implementation of 100% air tightness (leak) inspection
  • Spatter removing process is necessary.

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Enhanced air tightness at joining section
  • Abolition of air tightness (leak) inspection process
  • Abolition of process of removing spatters from hub's sliding section
TOP
Turbo impeller shaft Material (Joining dimension):Inconel713C×SCM440H(18×t4)
Application: Engine system parts
Pre-friction joining method/Problems

Grinding out of solid lost wax stock

  • Difficulty of grinding
  • Higher material cost as solid item
  • Cooling is necessary at shaft side of solid item.

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Expensive material can be used only for impeller as a result of dividing.
  • Since dividing allows using hollow material at joining section, effect of heat insulation at shaft side is enhanced.

Gearshift lever Material (Joining dimension):S35C×SS400D(10)
Application: Engine system parts
Pre-friction joining method/Problems
Grinding out from solid forging stock
?Higher material cost as solid item
?Larger number of machining man-hour

 
Category
Quality Cost Lightening
?  
Purpose and effects
?Friction joining of two finished items owing to dividing
?Reduced machining cost

Propeller shaft Material (Joining dimension):S35C×STKM13B×S35C(65×t1.6)
Application: Drive system parts
Pre-friction joining method/Problems

CO2 arc welding

  • Larger amount of unbalance
  • Many kinds of fitting shape at yoke joint
  • Difficult to find welding defect

 
Category
Quality Cost Lightening
Purpose and effects
  • Reduced amount of unbalance
  • Unification of shapes at joining section of yoke to butt joint
  • Zero release of defective parts by management of friction joining conditions
  • Weight reduction owing to increased joining strength

Constant velocity universal joint Material (Joining dimension):S45C×S48C(25)
Application: Drive system parts
Pre-friction joining method/Problems
Grinding out from solid forging stock
?Higher forging cost
?Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Housing section has been made sharable by dividing for adaptation to mass production.
  • Reduced number of dies in stock by making forging dies sharable
  • Optimization of forging blanks
  • Reduced number of machining man-hour

Rear axle shaft Material (Joining dimension):S43C×S43C(28)
Application: Drive system parts
Pre-friction joining method/Problems
Grinding out from solid forging stock
?Higher forging cost
?Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Forging of flange section only by dividing. Conversion to dividing
  • Reduction of forcing cost
  • Optimization of forged blanks

Side gear Material (Joining dimension):S45C×S45C(48×t7)
Application: Drive system parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Higher forging cost
    Larger number of man-hour in gear-cutting process

 
Category
Quality Cost Lightening
?  
Purpose and effects
  • Cold forging of common gear section by dividing for adaptation to mass production
  • Reduced forging cost
  • Abolition of gear-cutting process
  • Easier adaptation to varying pipe lengths
Drive shaft Material (Joining dimension):S45C×STKM41×S45C(40×t3.2)
Application: Drive system parts
Pre-friction joining method/Problems

CO2 arc welding

  • Larger unbalance amount (Correction of distortion is necessary.)
  • Spatter removal process is necessary.

 
Category
Quality Cost Lightening
Purpose and effects
  • Reduced unbalance amount
  • Abolition of processes for correction of distortion and spatter removal
TOP
Tulip shaft Material (Joining dimension):SCr421×SCM435(40×t3.2)
Application: Drive system parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Larger dimensions at joint section (Larger mounting space)

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Optimization of materials and heat treatment by dividing
  • Size reduction of joint section by optimization of materials

Axle shaft Material (Joining dimension):S35×S35C(34×t6)
Application: Drive system parts
Pre-friction joining method/Problems

Grinding out from solid round bar

  • Heavier gross weight

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Weight reduction by dividing and use of hollow material
  • Noise reduction by employing hollow material which is effective to absorb vibration during torque transmission

Outboard joint Material (Joining dimension):S43C×S43C(45)
Application: Drive system parts
Pre-friction joining method/Problems
Grinding out from solid forging stock
?Higher forging cost
?Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Making the housing section sharable by dividing for adaptation to mass production
  • Reduction of number of dies in stock by making them sharable
  • Optimizing of forging blanks
  • Reduced number of machining man-hour

Rear axle housing Material (Joining dimension):STKM45×SPH45×STKM45(70×t4.2)
?Application: Chassis system parts
Pre-friction joining method/Problems

CO2 arc welding

  • Oil leak from un-welded section
  • Implementation of 100% leak inspection
  • Higher cost of welded sections (edge preparation, number of parts, etc)

 
Category
Quality Cost Lightening
 
Purpose and effects
?Improvement of air tightness at joining section
?Abolition of leak inspection process
?Abolition of processing/reduced number of parts

Rear axle housing end Material (Joining dimension):S45C×STKM45×S45C(75×t4.2)
?Application: Chassis system parts
Pre-friction joining method/Problems

CO2 arc welding

  • Oil leak from un-welded section
  • Higher cost of end bearing boring process
  • Heavier weight of welded spigot section

 
Category
Quality Cost Lightening
Purpose and effects
  • Improvement of air tightness at joining section
  • Cost reduction by friction joining of all end machined items
  • Cost reduction by reduced number of processes
  • Weight reduction by employment of butt and friction joining

Steering shaft Material (Joining dimension):S43C×S43C(28)
?Application: Chassis system parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Higher forging cost
  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Conversion to cold forging of yoke section by dividing
  • Enhancement of joining quality
  • Reduced machining cost

Steering rack shaft Material (Joining dimension):SCr415×STKM13C(21.7×t3.2)
?Application: Chassis system parts
Pre-friction joining method/Problems
Grinding out from solid round bar
  • Larger man-hour of gun drill machining
  • Higher tool cost
  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Abolition of gun drill process by changing to divided pipe joining
  • Completion of gear cutting and heat treatment at rack section before joining
  • Reduction of tool cost
  • Reduced machining cost

Drag link Material (Joining dimension)):S45C×S45C×S45C(40)
?Application: Chassis system parts
Pre-friction joining method/Problems

Higher cost of upset forging

  • Higher cost of upset forging
  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Mass production forging of head as separate item
  • Reduced machining cost

Radius rod Material (Joining dimension):S45C×STKM13A×S45C(38×t6)
?Application: Chassis system parts
Pre-friction joining method/Problems

Flash butt welding

  • Problem of welding defect
  • Edge preparation is necessary.
  • Inferior appearance of joining section

 
Category
Quality Cost Lightening
 
Purpose and effects
?Enhancement of joining quality (No joining defect)
?Reduction of base material cost
?Enhancement of appearance at joint section

Brake torque plate Material (Joining dimension):S35C×S35C(34×t6)
?Application: Chassis system parts
Pre-friction joining method/Problems

Newly designed product

  • Screw connection on comparable products fragility to bending load

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Cleared continued bending load of 30 -1,200,000 cycles
  • oining of finished item (Cost reduction)

Torque rod Material (Joining dimension):S43C×S43C(45)
?Application: Chassis system parts
Pre-friction joining method/Problems

Flash butt welding

  • Problem of welding strength defect
  • Higher forging cost
  • Adhesion of spatters

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Enhancement of joining strength and accuracy
  • Cost reduction by simplifying forging form
  • No adhesion of spatters
  • Enhancement of appearance at joining section
TOP
Absorber rod Material (Joining dimension):SS400×S35C(22×t3.4)
?Application: Chassis system parts
Pre-friction joining method/Problems

Grinding out from solid round bar

  • Heavier gross weight

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Use of pipe at center by dividing (Weight reduction)

Torsion bar Material (Joining dimension):S45C×SUP435(14)
?Application: Chassis system parts
Pre-friction joining method/Problems

Machining after upset forging of header

  • Spline cutting
  • Higher manufacturing cost

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Change to rolling of end spline by dividing
  • Reduced machining cost

Clutch hub Material (Joining dimension):SPH45×S53C(21×t3)
?Application: Air conditioner part
Pre-friction joining method/Problems
Newly designed product

-

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Joining after machining spline
  • Possible reduction of cost

Connecting rod Material (Joining dimension):SWRM435×S45C×SWRM435(6)
?Application: Air conditioner part
Pre-friction joining method/Problems

Grinding out from solid cold rolled stock

  • Inferior globular accuracy and larger sliding resistance
  • Higher costs of machining and heat treatment

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Enhanced accuracy owing to use of steel ball
  • Reduced machining cost

Inflator Material (Joining dimension):SPFC×SPFC(80×t2.5)
???:Other parts
Pre-friction joining method/Problems

Newly designed product

  • Other machining methods are used on comparable products
    (Laser welding, electron beam, etc)

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Increased capacity to maintain air tightness

Jack spindle Material (Joining dimension):S35C×S35C(15)
Application: Other parts
Pre-friction joining method/Problems

Grinding out from solid stock

  • Higher thread turning cost

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Cost reduction by changing to rolling of threaded section
  • Use of joining burrs as stopper
TOP