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This document introduces the main components of the tooth forming mold. It includes diagrams of the configuration before and during molding, explaining the casting production of gears. Additionally, specific explanations regarding the configuration diagrams are also included, so please take a moment to read through it. [Contents] ■ Main configuration diagram of the tooth forming mold *For more details, please refer to the PDF document or feel free to contact us.

• Other molds

This document introduces the main components of the crowning molding die. It includes diagrams of the configuration before and during molding, explaining the forging production of gears. Additionally, specific explanations regarding the configuration diagrams are also provided, so please take a moment to read through it. [Contents] ■ Main components diagram of the crowning molding die *For more details, please refer to the PDF document or feel free to contact us.

• Other molds

If you have any questions regarding cold forging, please consult Clear Tech. Feel free to ask about anything, such as "I can't do this" or "I want to improve workability." We will definitely be of help to you by utilizing our extensive experience and know-how. We handle everything from mold design to process design and equipment selection. We will develop a highly complete system. 【Products forged with Clear Tech molds (partial list)】 ■ Bevel pinion gear: φ52×28.5 ■ Difficult-to-machine aluminum shapes: φ114.5×56 ■ Ratchet shapes: φ24×13 ■ Female dog gear with reverse slope: φ80×22 ■ Male dog gear: φ51×35 *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

At Clear Tech, we clarify the issues with existing molds and, if necessary, will produce corresponding molds. Ideal for customers who are troubled by the short lifespan of their currently used molds. We respond to requests to reduce running costs as much as possible. Please feel free to contact us. 【Products forged with Clear Tech molds (partial list)】 ■ Bevel pinion gear: φ52×28.5 ■ Difficult-to-machine aluminum shapes: φ114.5×56 ■ Ratchet shapes: φ24×13 ■ Female dock gear with reverse slope: φ80×22 ■ Male dock gear: φ51×35 *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

At Clear Tech, we design and manufacture any die set regardless of the forging method, such as sealing or blocking, or the size of the press. The die set used to set the mold in the press is an important component that affects the precision of the forged products and the lifespan of the mold. Customers looking for die sets are welcome to contact us. 【Products forged with Clear Tech molds (partial list)】 ■ Bevel pinion gear: φ52×28.5 ■ Difficult-to-machine aluminum shapes: φ114.5×56 ■ Ratchet-shaped products: φ24×13 ■ Female dock gear with reverse slope: φ80×22 ■ Male dock gear: φ51×35 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

At ClearTech, we leverage our high technical skills and extensive experience to achieve speedy transitions. Forging has three temperature ranges: hot, warm, and cold, each with its own characteristics, and the processes and mold designs vary accordingly. We can accurately assess whether a transition to warm or cold forging is possible, the associated costs, and the necessary equipment. [Products forged with ClearTech molds (partial list)] ■ Bevel pinion gear: φ52×28.5 ■ Aluminum difficult-to-machine shaped products: φ114.5×56 ■ Ratchet-shaped products: φ24×13 ■ Female dock gear with reverse slope: φ80×22 ■ Male dock gear: φ51×35 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Forging has three temperature ranges: hot, warm, and cold, each with its own characteristics, which also change the processes and the design of the molds. At ClearTech, we leverage our high technical skills and extensive experience to accurately assess whether a switch to cold or warm forging is feasible, the associated costs, and the necessary equipment, enabling a swift transition. This is ideal for customers considering a switch from hot forging to cold or warm forging. [Products forged with ClearTech molds (partial list)] ■ Bevel pinion gear: φ52×28.5 ■ Difficult-to-machine aluminum shapes: φ114.5×56 ■ Ratchet shapes: φ24×13 ■ Female dock gear with reverse slope: φ80×22 ■ Male dock gear: φ51×35 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

One of ClearTech's goals is "cutting-less." By producing high-precision forged products, we aim to reduce reliance on cutting processes. By minimizing the cutting processes that typically follow the forging process to the utmost limit, we will achieve further cost reductions. Customers aiming for net shape are encouraged to feel free to contact us. [Products forged with ClearTech molds (partial list)] ■ Bevel pinion gear: φ52×28.5 ■ Difficult-to-machine aluminum shapes: φ114.5×56 ■ Ratchet-shaped products: φ24×13 ■ Female dog gear with reverse slope: φ80×22 ■ Male dog gear: φ51×35 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company provides total support from the design of cold forging processes tailored to customer needs, to mold design and manufacturing, and finally to the completion of forged products. This is ideal for customers considering switching from machining to cold forging. We also respond quickly to design changes after mass production begins. Please feel free to contact us with your requests. 【Products forged with Clear Tech molds (partial list)】 ■ Bevel pinion gear: φ52×28.5 ■ Difficult-to-machine aluminum shapes: φ114.5×56 ■ Ratchet shapes: φ24×13 ■ Female dock gear with reverse slope: φ80×22 ■ Male dock gear: φ51×35 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Introducing the EDF method (Elastic Deformation for Forging) for the molding technology of precision forged gears utilizing elastic deformation of molds. Developed in 1988, it is fundamentally a sizing method after rough tooth molding. By pressing the tooth profile die along the inner diameter taper of the outer die with a punch, it is possible to apply strain to the tooth profile from the radial outward direction, preventing pressure differences in the vertical direction due to friction. 【Effects】 ■ Reduces the amount of re-melting, helping to decrease CO2 emissions by eliminating chip generation. ■ Paves the way for weight reduction. ■ There is less imbalance in the left and right teeth regarding quenching strain. ■ Gears have long suffered from gear noise, but this method is expected to be beneficial in that area as well. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

At Clear Tech, we are currently challenging the cold forging of "ring gears" that are manufactured through cutting processes. The successful prototype of the cold forging method shapes both the inner and outer teeth simultaneously. The direct effects include improved material yield, reduced gear noise, and increased strength, while indirect benefits are expected in terms of environmental impact, miniaturization, and cost reduction. The specific shaping method involves a two-step cold forging process, completing the inner helical gear and outer spur gear. In the first step, the outer and inner teeth are simultaneously formed on a ring-shaped material, and in the second step, a sizing process is planned to achieve the required precision for the gears. [Effects of Development] ■ Improved material yield ■ Reduced gear noise ■ Increased strength ■ Indirectly, effects on the environment, miniaturization, and cost reduction *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

In cold forging, not only the cost but also the strength of the gears and the surface quality of the tooth surfaces are improved. The effective contact area of the gears increases, and even when transmitting the same power, the local stress decreases, making it less likely for tooth surface fatigue to occur, which is expected to result in increased strength. Furthermore, the ability to freely shape the tooth root is also believed to contribute to increased strength. 【Features】 ■ Processing can be done without interrupting the flow ■ Tooth surface fatigue is less likely to occur, leading to increased strength ■ The ability to freely shape the tooth root also contributes to increased strength *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Our company has achieved a cutting-free process by realizing all stages through cold forging. Products shaped to net shape through cold forging have higher fatigue strength compared to machined products and possess a smooth surface finish, making them less prone to surface fatigue (chipping). Furthermore, considering the introduction of specialized machines such as hobbers and gear shapers, cost reductions in equipment investment can also be realized. 【Features】 ■ No chips produced ■ Approximately 35% less material used compared to machined products ■ Increased fatigue strength and a smooth surface finish ■ Cost reductions in equipment investment achieved *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Through our diverse achievements and experiences in the development of various forged products, we discovered that as the forging temperature increases, the friction force decreases. In a practical example, during cold forging utilizing friction, when the mold temperature was raised to 80°C to forge a helical gear, the extrusion load decreased by more than 50% compared to room temperature. Additionally, in a situation where a press-fitted mold could not be disassembled at room temperature, heating the entire mold to 200°C reduced the load by about 30%, allowing the mold to be disassembled. Details are introduced in the related links. [Examples] - When the mold temperature was raised to 80°C to forge a helical gear, the extrusion load decreased by more than 50% compared to room temperature. - In a situation where a press-fitted mold could not be disassembled at room temperature, heating the entire mold to 200°C reduced the load by about 30%. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

We would like to introduce a case study on the improvement of mold lifespan that we conducted. The mold before improvement, which was a single piece, was prone to fatigue failure due to significant shear strain caused by the horizontal stress component generated by the forging internal pressure. In the improved mold, by adopting a design that is split into upper and lower parts, we were able to avoid large shear strain and prevent fatigue failure. 【Case Overview】 ■ Issue: Prone to fatigue failure due to large shear strain in the S cross-section ■ Results - Designed to be split into upper and lower parts, avoiding large shear strain - Achieved significant improvement in mold lifespan *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce our cold forging technology, "Improvement of Extruded Forged Gears." In the extrusion forging of helical gears, the tooth profile mold is twisted, causing the pressure during the press extrusion to differ between the upper and lower parts of the mold teeth. The pressure is higher at the top and lower at the bottom, resulting in a twisted shape. As a countermeasure for the shape issue, we set the necessary amount of taper to the mold immediately after extrusion and used this taper for shaping to correct the shape. As a result, the upper and lower surfaces of the gear became rectangular, and the burrs were reduced. 【Technical Overview】 ■ Issue: Twisting of the shape in the extrusion forging of helical gears ■ Countermeasure: Setting the necessary amount of taper to the mold immediately after extrusion ■ Result: Reduced the thickness and the burrs that protrude *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce our cold forging technology, "Dimple Forming on Gear Tooth Surfaces." By applying dimple forming to gear tooth surfaces, we can expect a reduction in the friction coefficient. If we can lower the friction coefficient, it is possible to reduce gear noise in gearboxes for electric vehicles (EVs) and other applications. This is expected to significantly contribute to the lightweighting of gears. 【Features】 ■ In dimpled forged surfaces, hydraulic pressure increases under load. ■ A lubricating film forms on the surrounding contact surfaces, reducing the friction coefficient. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

We will introduce the basic knowledge and features of cold forging. Cold forging refers to forging performed at room temperature, allowing for production with minimal material. It has the advantage of reduced loss due to machining. The accuracy during shaping is high, enabling shaping at the micrometer level, and eliminating the need for subsequent machining. Additionally, it is more suitable for relatively small items, and determining the intermediate shapes needed to achieve the desired final shape requires advanced technology and experience backed by theory. 【Advantages】 - Production with minimal material (reduced loss due to machining) - High accuracy during shaping - Shaping at the micrometer level - Net shape (no subsequent machining required) *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

ClearTech Co., Ltd. manufactures forging molds based on the technology and experience accumulated in cold forging. Recently, by utilizing our unique technique "EDF method," we have solved various issues related to forging molds. If you are facing challenges with cold forging, please feel free to consult with us. 【Advantages of Cold Forging】 ■ Can be manufactured with minimal material (less waste from machining) ■ High precision during shaping ・ Can achieve shaping in the order of 1μm ・ Net shape (no need for subsequent machining) *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company specializes in cold forging. By using the EDF method, we can manufacture precision gears, such as those for transmissions, through cold forging. This allows for reduced costs due to less cutting, shortened processes, and more. Please feel free to consult us about anything related to cold forging. 【Benefits of Cold Forging】 ■ Can be manufactured with minimal material (less waste from cutting) ■ High precision during shaping ・ Can achieve shaping in the 1μm range ・ Net shape (no need for subsequent cutting) *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

ClearTech Co., Ltd. strongly supports your manufacturing through the design, development, and production of cold forging molds. If you want to extend the mold life, achieve net shape, shorten processes, need a forging die set, want to switch from machining to cold forging, or are looking to start a new cold and warm forging business, please feel free to consult with us regarding any issues related to cold forging. Company visits are also welcome. 【Benefits of Cold Forging】 ■ Can be manufactured with minimal materials (less waste from cutting) ■ High precision during shaping ・Can achieve shaping at the 1μm level ・Net shape (no post-machining required) *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Advanced cold forging technology can be applied to various molds based on accumulated data. By leveraging process and mold design capabilities, it achieves desired shapes and cost reductions. Benefits include: ■ Reduced cutting (approximately 35% less material) ■ Increased toughness and improved strength ■ Extended mold lifespan ■ Shortened processes, among others.

• Forging Machine