Records of achievements

Machinery components


Back roller Material (Joining dimension):S45C×SS400×STKM38(152.4×t3.2)
?Application: Textile machine parts
Pre-friction joining method/Problems

Solid forging item is shrink-fit to and caulked on a pipe with parallel pins.

  • Employing pipes of thick wall, the fitting section is machined.
  • Heavier product weight
  • Problem of defective parts occurring at shrink-fit process

 
Category
Quality Cost Lightening
Purpose and effects
  • Reduction of base material cost by dividing (Abolition of forging)
  • Joining section is finished in the form of butt joint.
  • Light weight owing to the use of thin wall pipes
  • Reduced fraction defective

Feed roller Material (Joining dimension):S45C×S45C(14)
?Application: Textile machine parts
Pre-friction joining method/Problems

Grinding out of 28 round bar

  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Machining cost reduction by dividing

Copy roller (Stainless steel) Material (Joining dimension):SUS304×SUS304(50×t4)
?Application: Printing machine parts
Pre-friction joining method/Problems

Press fitting

  • Problem of sheet feed failure caused by air leak from fitting section
  • Machining is necessary at press fitting section.

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Abolition of pressure leak inspection process
  • Machining cost reduction

Copy roller (Aluminum) Material (Joining dimension):A6063×A6063(45×t4)
?Application: Printing machine parts
Pre-friction joining method/Problems
Press fitting

  • Problem of sheet feed failure caused by air leak from fitting section
  • Machining is necessary at press fitting section.

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Abolition of pressure leak inspection process
  • Machining cost reduction

Copy roller (Steel) Material (Joining dimension):S15C×STKM13B×S15C(14×t1.6)
?Application: Printing machine parts
Pre-friction joining method/Problems

Press fitting

  • Problem of sheet feed failure caused by air leak from fitting section
  • Machining is necessary at press fitting section.

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Abolition of pressure leak inspection process
  • Machining cost reduction

Crank shaft (Compressor) Material (Joining dimension):
S15C×S15C×STKM13C(25-42×t9)
Application: Industrial machine parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Many kinds of forging die are necessary.
  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Press processing of weight section by dividing (Adaptation of weight section to mass production)
  • Reduced number of machining man-hour
  • Weight reduction by the use of pipe
TOP

 

Ball screw Material (Joining dimension):S45C×S45C(32)
?Application: Machine tool parts
Pre-friction joining method/Problems

Grinding out from solid stock

  • Higher turning cost of threaded section

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Cost reduction by turning the threaded section

Hook Material (Joining dimension):S15CK×S15CK(10)
?Application: Sewing machine parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Cold rolling of hook section by dividing
  • Reduced number of machining man-hour

Needle bar Material (Joining dimension):STKM11A×S45C(6.6×t1.0)
?Application: Sewing machine parts
Pre-friction joining method/Problems

Grinding out from solid round bar

  • Larger number of machining man-hour
  • Difficult to bore

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Use of thin-wall pipes by dividing
  • Abolition of boring process

Ball joint Material (Joining dimension):S35C×SUJ2(12)
Application: General purpose machine parts
Pre-friction joining method/Problems

Grinding out of solid round bar

  • Larger number of machining man-hour
  • Difficult to secure globular accuracy

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Reduced machining cost
  • Enhanced accuracy due to the use of steel balls

Joint Material (Joining dimension):STKM11A×S45C(7)
Application: General purpose machine parts
Pre-friction joining method/Problems

Grinding out of solid round bar

  • Larger number of machining man-hour

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Reduced machining cost by dividing

Guide roller Material (Joining dimension):S45C×S45C(145×t18)
Application: Construction machine parts
Pre-friction joining method/Problems
CO2 arc welding

  • Pre-heating process is necessary.
  • Larger deform after welding
  • Larger wall-thickness at fitting section (Heavier weight)

 
Category
Quality Cost Lightening
Purpose and effects
  • educed number of manufacturing processes
  • Adaptation to weight reduction
  • Enhancement of joining quality (Also appearance)

TOP

Bushing Material (Joining dimension):SPC1×SPC1(90×t3.2)
Application: Construction machine parts
Pre-friction joining method/Problems
rinding out from solid alloy casting

  • Higher base material cost
  • Problem of poor abrasion resistance

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Cladding of SPC stock with metal stock by dividing
  • Reduced base material cost
  • Enhanced abrasion resistance

Piston rod Material (Joining dimension):S45C×S45C(125)
Application: Construction machine parts
Pre-friction joining method/Problems
CO2 arc welding

  • Edge preparation and fitting processes are necessary.
  • Poor strength at joint section (Smaller effective joint area)
  • Problem of dispersed or adhered spatters

 
Category
Quality Cost Lightening
 
Purpose and effects
  • No edge preparation and fitting is required.
  • Increased strength at joint section
  • Abolition of spatter removal process

Wheel shaft Material (Joining dimension):S45C×SCM435(60)
Application: Agriculture machine parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Higher forging cost
  • Larger number of man-hour for die matching, deburring, etc.

 
Category
Quality Cost Lightening
   
Purpose and effects
  • Forging of flange section only by dividing
  • Reduced forging cost
  • Optimization of forging blank
  • Reduced number of machining man-hour

Sprocket Material (Joining dimension):SS400×SPC1×STK45(92×t2-40×t7.2)
Application: Agriculture machine parts
Pre-friction joining method/Problems

Grinding out from solid forging stock

  • Larger number of machining man-hour
  • Heavier weight

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Press fitting of finished item by dividing
  • Base material is suitable because it is deformation-processed.
  • Reduced number of processing man-hour
  • Reduced product weight

Axle shaft Material (Joining dimension):S45C×S45C×SCM435(40)
Application: Industrial vehicle 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 only by dividing
  • Adaptation to mass production by the use of common flange
  • Reduced number of processing man-hour
  • Use of alloy steel at spline section only

Hydraulic cylinder piston rod Material (Joining dimension):S45C×S45C(50)
Application: Industrial vehicle parts
Pre-friction joining method/Problems
CO2 arc welding

  • Insufficient welding strength
  • Spatter removal process is necessary.

 
Category
Quality Cost Lightening
 
Purpose and effects
  • Enhanced joining strength
  • Abolition of spatter removal process
TOP