Case1

Integrated processing of two-piece parts by ironing technology  (quality performance up)

Field of application

VE idea point

・Tube for strad suspension    ・Pipe with bottom

・Integration of 2 parts (actual result up to S25C)
・The accuracy of the inner and outer diameter is increased. (25micron dimentional accuracy possible for inner and outer diameter)
・The integration improves the reliability of joint by old method.
・Inner dimeter surface roughness is good.(inner surface roughness is 0.6a below)

※Ironing processing time is longer than cold forging.
　(Around 20sec)
※The number of ironing increases due to area reduction rate.

  Existing method

 2 pieces(pipe cap) were joined by welding.

New technology/New method

  It can be integrated into the shape after welding by cold forging+Ironing.

Strad suspension
≪Inner tube welding portion≫

Strad suspension
≪Inner tube integrated shape≫  

≪Section of welding portion≫

≪Section of integrated shape≫

Item

Cost

Productivity/
Workability

Quality/
Performance

Environmental
impact

Others

Numeric ratio

Cost reduction
depending
on condition

20% decrease

30% improved

Case2

 Hardness up and cost reduction by cold forging

Field of application ​

VE idea point

・Cam cap group
・Bracket group

・Applicable to high strength material such as 2000 series alloy.
・Initial investment (die cost) is cheaper than Die-Casting.
・Possibility of further cost reduction by drilling "punching"

※Because extruded material is used, the material cost is higher than casting material.
※Cold forging is not suitable for excessively complex shape.

  Existing method

  In the existing method, it is manufactured by casting (Die-Casting), 1.Hardness is decreased from casting porosity. 2.There was problem such as the necessity of increasing thickness for hardness assurance.

 New technology/New method

Aluminum cold forging achieved to improve part reliability and reduce weight.

Product drawing

Aluminum cold forging part photo

Item

Cost

Productivity/
Workability

Quality/
Performance

Environmental
impact

Others
(Reliablity)

Numeric ratio

10% decreased