株式会社酒井鉄工所 List of Products and Services

We have launched "Pocket Factory" with the desire to "increase the efficiency of machinery and provide services that can be of help to everyone in the world." The first offering is "6F board + hole processing." For the time being, we are narrowing down the materials, sizes, and types of processing we handle, but in response to customer requests for "I need it quickly," our staff from reception to the factory will work together to address each request promptly and carefully. If you have any opinions or requests such as "I would like to see this material handled" or "I would be happy if this type of processing could be done," we would be grateful if you could share them with us without hesitation. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

The standard deviation refers to "how much variation there is in relation to the average value." The method for calculating the standard deviation involves the following steps: "calculate the average," "calculate the deviation (the difference from the average)," "calculate the variance (the average of the squared deviations)," and "calculate the standard deviation (taking the square root of the variance)." In the special grade of the skills assessment, this is something that must be memorized regardless of the occupation. Even those who are not good at math can calculate it by following the correct steps, so why not give it a try? You can view detailed information through the related links, so please take a look. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

"Lead time" is also referred to as procurement period, which is the time from when the customer places an order to when it is delivered. "Shop time" is the time from when materials arrive at the factory to when they are shipped to the customer. In our manufacturing industry, to respond to short delivery times (reducing lead time), the time that can basically be shortened is shop time, which depends on how quickly we can process materials after they arrive. Currently, the mainstream approach is to increase machine operating rates through IoT and reduce waiting time losses, aiming to eliminate waste in production. For more detailed information, please refer to the related links. *For more details, please check the PDF materials or feel free to contact us.

• Processing Contract

An internal grinding machine is a type of machine tool used for grinding the inner surfaces of holes, and some models can perform end face grinding to ensure the perpendicularity between the hole's axis and its end face. By grinding the end face and the hole simultaneously, high-precision machining can be achieved. Additionally, unlike honing, the positional accuracy of the hole does not depend on prior processing (previous steps) and can accommodate various hole diameters with a single grinding wheel. The size that can be ground is determined by the diameter of the grinding wheel and the machine's stroke, allowing for the grinding of stepped shapes and tapered surfaces, which is one of the features that enables precise coaxiality (concentricity). For more detailed information, please refer to the related links. *For more details, please check the PDF materials or feel free to contact us.*

• Grinding Machine

A cylindrical grinding machine is a type of machine tool that can grind the outer shape (cylinder) and taper of round objects. There are two main grinding methods for cylindrical grinding machines, which are largely categorized based on the relationship between the grinding wheel and the movement of the workpiece. In centerless grinding, processing cannot be done if there are grooves, but with a cylindrical grinding machine, processing can be performed even if there are grooves, as it involves chucking. For more detailed information, please refer to the related links. *For more details, please check the PDF materials or feel free to contact us.*

• Grinding Machine

We would like to introduce the process of cutting external threads on a conventional lathe by a craftsman. We use brazed cutting tools instead of throwaway inserts for this work. If you can perform this task, there is no need to match the sizes of the dies. While it is possible to cut threads on a CNC lathe, the conventional lathe is faster and easier. You can view detailed information through the related links, so please take a look. *For more details, please refer to the PDF materials or feel free to contact us.

• lathe
• Processing Contract

Centerless grinding machines, also known as coreless grinding machines, are capable of grinding the outer shape of round objects without the need for chucks. The advantages of centerless grinding include "no need for centering, making it manageable even for inexperienced operators," and "less grinding allowance, resulting in less wear on the grinding wheel." Although the precision may be somewhat inferior compared to cylindrical grinding machines, their high productivity and ability to grind elongated objects make them very useful. For more detailed information, please refer to the related links. *For more details, please check the PDF materials or feel free to contact us.*

• Grinding Machine
• Processing Contract

A grinding machine is a machine that finishes by rotating an abrasive wheel. Its features include the ability to process hard materials (such as those after hardening) that cannot be cut, and it can easily process items where achieving precision through cutting is difficult (on the micron level). Grinding not only meets dimensional tolerances and surface roughness but also varies the type of grinding machine based on the shape being processed, fulfilling geometric tolerances and other purposes. Broadly speaking, grinding machines are classified into three types: "flat," "outer diameter," and "inner diameter." Similar to lathes, the machines used differ based on purpose and application, so it is necessary to choose the appropriate one. For more detailed information, please refer to the related links. *For more details, please check the PDF materials or feel free to contact us.*

• Grinding Machine
• Processing Contract

On the website of Sakai Iron Works Co., Ltd., we introduce questions and answers. For example, "I would like to request everything from processing to painting and assembly?" is published in a Q&A format. You can view the detailed content through the related links, so please take a look. 【Published Content】 ■ I would like to request design services, is that possible? ■ I would like to request everything from processing to painting and assembly, is that possible? ■ Can you provide inspection records? *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

On the homepage of Sakai Iron Works Co., Ltd., we introduce questions and answers regarding our transactions. Starting with "Can you accommodate orders in small lots every month?" and including "What if there is a defect in the product?" we have published a Q&A format. You can view the detailed content through the related links, so please take a look. 【Published Content (Partial)】 ■ I would like to request processing, painting, and assembly, is that possible? ■ Can you accommodate orders in small lots every month? ■ Is the payment method already decided? ■ What if there is a defect in the product? ■ I would like to entrust you with the arrangement of materials. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

On the website of Sakai Iron Works Co., Ltd., we introduce questions and answers about processing technology. We have published a Q&A format starting with "Can you perform internal diameter slotting (key grooves)?" and including inquiries like "I would like to request processing, painting, and assembly, etc." You can view the detailed content through the related links, so please take a look. 【Published Content (Partial)】 ■ Can you perform internal diameter slotting (key grooves)? ■ I would like to request processing, painting, and assembly, etc.? ■ I would like to have machining done on a shaped material with a lathe finish? ■ I have large aluminum parts; can you process them? ■ It's not that big, but can you process it? *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a case study of deep hole machining of a nickel alloy shaft, SUS630, conducted at Sakai Iron Works Co., Ltd. The shaft was made of a difficult-to-cut material, and the deep hole with a diameter of 12 mm and a depth of 600 mm was quite challenging. When the material was SUS630, we used a gun drill. For the nickel alloy, we manufactured special tools in-house for the machining. Additionally, we offer one-stop production services for tasks such as "valve assembly work" and "integrated production of filling machine frames." 【Case Overview】 ■ Material: Nickel alloy, SUS630 ■ Size: Ф150×L700 ■ Quantity: 2 pieces ■ Process: NC lathe (rough) → MC → hardening (outsourced) → NC lathe (finish) → MC → cylindrical grinding *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a case study of grinding processing of cylindrical grinding machine challenge materials conducted at Sakai Iron Works Co., Ltd. It was very challenging to ensure precision with only lathe processing. This was delivered for educational purposes at Meister College in Kashiwazaki City. Additionally, we have other processing examples such as "flatness of 0.01 on a surface plate using a lapping machine" and "finishing of the inner diameter of a connecting rod by one-pass honing." Please feel free to contact us when you need our services. 【Case Overview】 ■Material: S45C, heat-treated ■Roughness: Ra6.3 ■Quantity: 10 pieces *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a machining case of mechanical parts with multiple geometric tolerances conducted at Sakai Iron Works Co., Ltd. Since the product had tolerances in various parts and required high precision, a cylindrical grinding machine was also used to meet the geometric tolerances. The accuracy was achieved through simultaneous processing. In addition, we also have NC lathe machining cases such as "shaft (maximum diameter φ360 L1600)" and "eccentric shaft." Please feel free to contact us when you need our services. 【Case Overview】 ■ Size: Ф100 L200 ■ Material: S50C ■ Inner Diameter: Ф70H6 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a metal processing case of "machine tool parts - bearings" conducted at Sakai Iron Works Co., Ltd. A machining center was used for rough machining during unmanned night operations. The parallelism and pitch of the shaft from the end face were processed to ±0.01. In addition, we also have processing cases for "hydraulic manifold blocks (material: SS400)." Please feel free to contact us when you need assistance. 【Case Overview】 <Machine Tool Parts - Bearings> ■Material: FC200 ■Size: 160×100×270 ■Quantity: 30 ■Tolerance: Squareness 0.01, Shaft diameter 60H7, etc. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a metal processing case of a large gear holder (material: AC2A) with a diameter of φ2300 conducted at Sakai Iron Works Co., Ltd. The gear holder is machined through large turning and is processed for holes and grooves using a five-sided machining center. Please feel free to contact us when you need our services. 【Case Overview】 ■Material: AC2A ■Size: Ф2300×H360 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a case of metal processing conducted at Sakai Iron Works Co., Ltd. In this case, we consistently manufactured 200 valves from processing to assembly. In addition to this, we also produce various other products up to the assembly stage. We perform assembly operations, adjustments, and inspections (leak tests), so please feel free to contact us when you need our services. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a case study of machining using a robotic arm. Since it can be processed through automated operation even at night, it is suitable for mass production. Our company has established a unique mass production system and manufactures a wide variety of cast iron pistons through unmanned operation. In addition to cast iron pistons, we also use robotic arms for mass production machining of products with a diameter of 150 mm or less. Please feel free to contact us when you need assistance. 【Case Overview】 ■ Size: Ф130×100 ■ Material: FCD700 ■ Quantity: 4000 pieces × 3 types *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

At Sakai Iron Works Co., Ltd., we use automatic lathes for mass production machining. The inner diameter of the sleeve is processed by honing, and the outer diameter of the spool is processed by centerless grinding, adjusting the clearance to a range of 2 to 5 μm. Please feel free to contact us when you need our services. 【Case Overview】 ■ Sleeve ・Inner Diameter: Ф9.341 ・Roundness: 0.4 μm ■ Spool ・Outer Diameter: Ф9.339 ・Roundness: 0.8 μm *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce a case study of metal processing conducted at Sakai Iron Works Co., Ltd. Due to variations in the distribution from the center of the casting hole and the material, there was a risk of positional deviation during machining. Therefore, we created a jig and manually tapped M3 threads. Please feel free to contact us when you need our services. 【Case Overview】 ■Material: FC250 ■Quantity: 30 units *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We will introduce a case of processing a ring with a diameter of 2.5m or more at Turning. The processing order is to first work on the end face, followed by the inner and outer diameters. This is to create a holding allowance during the end face machining for the inner and outer diameters. Until the thickness of the end face is uniform, we alternate between processing the front and back surfaces for 2 to 4 sets. Since large and slender rings are prone to distortion, the processing is not done all at once; we temporarily loosen the fixture and then re-tighten it lightly. After the thickness is uniform, we finish by machining the inner and outer diameters. ● For more details, please download the catalog or contact us.

• Processing Contract

This is an example of a process with a relatively high number of steps, ultimately assembling and machining two components. Height approximately 800mm, outer diameter of the disc part approximately 1200mm. (The diagram is a simplified version of the actual machined workpiece.) Due to the high precision required for the parallelism of the top and bottom surfaces after assembly, in Process 4, the top surface of the disc part is finished by turning after assembly. ● For more details, please download the catalog or contact us.

• Processing Contract

This is an example of machining white metal, which is thinly adhered to the inner diameter of a cylindrical workpiece using turning. The machining diameter is Φ900mm, the tolerance is 0.05mm, and the specifications for the finished surface are as follows. White metal, also known as Babbitt metal, is a soft material used in sliding bearings and other applications. Therefore, care must be taken to ensure that the chips generated during cutting do not scratch the machined surface. Measures such as adjusting the direction of chip ejection with the tool shape are implemented. ● For more details, please download the catalog or contact us.

• Processing Contract

This is an example of machining a gearbox using a five-sided machining center. The position of the horizontal hole is determined by the distance from the center of the hole in the center of the box. The tolerance width in the x-axis direction requires a high precision of 0.01. The positioning of the center of the hole in the center of the box is done from the vertical axis direction, and the machining is performed from the horizontal axis direction. This product would be very difficult to approach using a vertical machining center that only approaches from the top or a horizontal machining center that only approaches from the side. This is an example of machining that takes advantage of the high degree of freedom unique to a five-sided machining center, which can approach from both vertical and horizontal directions with a single chucking. For more details, please download the catalog or contact us.

• Processing Contract

We have accumulated a wealth of experience and achievements in small and round products. We can also accommodate a variety of materials, including difficult-to-machine materials. By somewhat limiting the size and shape, we can keep standard specifications in stock for quick response upon order. 【Parts handled】 ○ Bushings ○ Shafts ○ Valves ○ Flanges ○ Guide pins ○ Cocks ○ Tubes ○ Washers ○ Bolts ○ Nuts Of course, we also handle many special items that cannot be classified into these categories. We do not strictly define the range of "small items." If you consider something to be palm-sized, please feel free to contact us. ● For more details, please download the catalog or contact us.

• Processing Contract

In the processing operations, if the "lathe processing is requested from this factory and the machining processing is requested from that factory" separately, issues such as time loss, cost loss, and management problems between processes will arise due to the movement between factories. Sakai Iron Works Co., Ltd. is equipped with a wide variety of processing machines and specializes in integrated responses, so if you entrust your work to Sakai Iron Works Co., Ltd., all processing can be carried out entirely within the Sakai Iron Works factory. Furthermore, even in cases where there are processing operations that cannot be fully covered by Sakai Iron Works' equipment alone, since Sakai Iron Works belongs to a metal complex, we can minimize losses by collaborating with other factories within the complex. For more details, please contact us or refer to our catalog.

• Processing Contract

In the processing engineering, if the "lathe processing is requested from this factory and the machining processing is requested from that factory" separately, it can lead to time losses, cost losses, and management issues between processes due to the movement between factories. Our company is equipped with a wide variety of processing machines and specializes in integrated responses, so if you entrust us with your needs, we can carry out the processing entirely within our factory. Furthermore, even in cases where there are processing processes that cannot be fully covered by our equipment alone, we belong to a metal industrial complex, allowing us to minimize losses by collaborating with other factories within the complex.

• Casting Machine

In the manufacturing process, if the "lathe processing is done at this factory and the machining processing is done at that factory" is requested separately, it can lead to time losses, cost losses, and management issues between processes due to the movement between factories. Our company is equipped with a wide variety of processing machines and specializes in providing integrated solutions, so if you entrust us with your needs, we can carry out the entire processing within our factory. Furthermore, even in cases where there are processing steps that cannot be fully covered by our equipment alone, we belong to a metal industrial complex, allowing us to collaborate with other factories within the complex to minimize losses.

• Casting Machine