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Manufacturing automobile parts by advanced micro-controlled heading techniques

Designing and development

Designing and development

Ideas to Reality, Know-how to Quality

tapping

Based on creation and research only human hands can achieve, Fuserashi's problem-solving team offers solutions to meet its customers' needs. Furthermore, Fuserashi has realized a short lead time and cost efficiency by fully utilizing its cutting edge 3D analysis system.

CF (Cold Forming)

Cold Forming is a method of deforming coiled materials at a normal temperature with continuous force above a set level.
Deforming is a method of metallic material processing that renders a metal incapable of returning to its original shape through bending, stretching or beating the material with a force above a set level.
Because the whole material is processed, Cold Forming causes less waste of materials than cutting processes and less heat distortion than hot forging or warm processing. This process also requires less processing time.

HF(Hot Forming)

Hot Forming is a method of processing heated materials. This method makes use of heat to soften the material in order that it may be processed more easily. Materials are heated to a little higher than the transformation temperature (point of metallic organization transformation) but a little lower than the point where the material starts melting, and are formed by using continuous force above a set level.

MP(My Press)

My Press is a process where metallic materials inserted into a die are pressed at a normal temperature with a force above a set level in order to meet required forms and dimensions. Because materials’ resistance to deformation is strong at normal temperatures, the change rate is smaller than in Hot Forming, and each stage of this process is subject to shape restrictions.
However, this method is highly productive and realizes high dimensional accuracy, while attaining a smooth surface.
These strong points greatly shorten machine processing operations allowing this method to achieve high yield rates.

TP(Tapping)

In most automatic nut tappers, a tapping blade tool called a bent tap rotates and threads.
Threaded nuts fix the tap shank, thereby, enabling continuous tapping.


Merits and Demerits of forming

Merits

  • Processing speed is high and very productive making it suitable to mass production.
  • Even for mass production only a small quantity of machines are required.
  • Materials are not cut in this process, and thus can be effectively utilized with very small waste.
  • Compared to other processing methods, parts can be produced at lower cost when parts specifications, quantities, etc. match forming process conditions.
  • Product strength is raised because parts are hardened at forming and the fiber flow of metal materials are not disconnected.

Demerits

  • Unsuitable to small quantity production because labor and time are required for machine arrangement and adjustment.
  • An initial tooling cost is needed, and trial production takes time.
  • As the deformation rate of material is limited, shapes and precision are restricted.

Comparison between forming and die-casting

Merits

  • High density and superior mechanical properties
  • Possible to use steel and other materials unusable in die-casting
  • Possible to produce thick-shaped parts
  • Stable interior quality

Demerits

  • Not possible to produce complicated shapes such as die-cast parts
  • Not possible to reuse material
  • Difficult to produce thin-shaped parts such as die-cast parts