株式会社東亜鍛工所　新井工業株式会社 List of Products and Services

Our company, with 51 years of experience and precision forging technology, offers a comprehensive service from mold design and manufacturing to mass production, forging, heat treatment, machining, and finished products. We can produce high value-added products generated from improvements, even in small lots. We have compiled a collection of 18 examples of "forging cases" using our precision forging and forming technology for industrial machinery, building materials, construction machinery, agricultural equipment, and automotive parts into a document! ▼ Do you have any of these concerns? - Want to reduce procurement costs - Want to decrease the number of machining equipment for parts - Want to reduce man-hours, work-in-progress, and quantities - New product development in small lots - Integration of parts We will introduce examples such as the "coupler," which shapes a concave form through forging and reduces the weight of the setup using rolling methods, and the "shaft gear," developed by integrating four parts. Additionally, we will also present the "hypoid gear," a drive system component whose yield has improved through hot forging and rolling forming, along with photos. ★ You can view the collection of processing examples by downloading the PDF below.

• Processing Contract

Our company, with years of cultivated experience and precision forging technology, provides a seamless service from mold design and manufacturing to mass production. We can produce high value-added products generated from improvements, even in small lots. We offer one-stop solutions for multi-process, multi-component, and multi-sourced products, contributing to reduced man-hours, shortened time, and cost reduction. This document introduces examples such as creating drawings from actual agricultural special vehicle parts without existing blueprints and carrying out mass production, as well as a case where we were consulted about whether a product originally composed of four parts could be forged all at once. [Contents (partial)] ■ Story of the solution case.01 - Hypoid B&P set (bevel gear & pinion gear) ■ Story of the solution case.02 - Straight B&P set (gear and shaft for a machine that removes weeds from rice fields) *The collection of solution cases can be viewed via the "PDF Download" link below.

• Contract manufacturing

Our company, with years of cultivated experience and precision forging technology, offers a seamless response from mold design and manufacturing to mass production. We can produce high value-added products generated from improvements, even in small lots. We provide one-stop solutions for multi-process, multi-component, and multi-sourced products, contributing to labor reduction, time savings, and cost reduction. We have compiled a collection of processing examples showcasing our precision forging and forming technology, including forged cases for construction steel pipe components, agricultural machinery, and automotive parts. Examples include a "coupler" that reduces weight through the formation of concave shapes via forging and rolling methods, and a "shaft gear" developed by integrating four components. Additionally, we present the "hypoid gear," a drive system component that has improved yield through hot forging and rolling forming, complete with photographs. ★ Please view the collection of processing examples via the "PDF Download" link below.

• Processing Contract

We would like to introduce a case study of the "Nozzle Clamper" manufactured by our company. The manufacturing process involves hot forging and cold sizing, and the application is for automotive parts. One of its features is improved productivity by producing multiple pieces at once. Additionally, the sizes we can manufacture range from 30 to 100 mm and weights from 50g to 500g. Please feel free to contact us if you have any requests. 【Case Overview】 ■ Material: SCM4 type ■ Application: Automotive parts ■ Manufacturing Process: Hot forging + Cold sizing ■ Available Sizes: 30 to 100 mm, 50g to 500g ■ Orderable Lot: From 300 pieces ■ Features: Improved productivity by producing multiple pieces at once *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the "coupler" products manufactured by our company. We shape concave forms through forging (Φ165 to Φ190) and reduce the weight through rolling methods (Φ200 to Φ355). The material used is construction steel. Additionally, the sizes we can manufacture range from Φ165 to Φ355, weighing between 3kg and 11kg. Please feel free to contact us if you have any requests. 【Case Overview】 ■ Material: Construction steel ■ Application: Construction steel pipe components ■ Manufacturing Process: Hot forging ■ Available Sizes: Φ165 to Φ355, 3kg to 11kg ■ Minimum Order Quantity: 300 or more ■ Features: Concave shapes formed by forging, weight reduction through rolling methods *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the "Bevel Gears & Pinion Gears" products manufactured by our company. The manufacturing process includes hot forging + gear cold sizing + race processing + carburizing. The possible manufacturing sizes range from Φ100 to Φ220, and weights from 1.5kg to 10kg. A notable feature is that the gear grinding and lapping processes have been eliminated, resulting in no cutting processes at all (precision gear forging). 【Case Overview】 ■ Material: SCM ■ Application: Reduction gear ■ Manufacturing Process: Hot forging + gear cold sizing + race processing + carburizing ■ Possible Manufacturing Sizes: Φ100 to Φ220, 1.5kg to 10kg ■ Minimum Order Lot: 300 or more ■ Features: Elimination of gear grinding and lapping processes, no cutting processes at all, JIS Class 2 precision *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a product case of "Bevel Gears & Pinion Gears" manufactured by our company. The material used is SCM, and the manufacturing process includes hot forging + race processing + broaching + carburizing heat treatment. The available size is up to Φ200. These products are suitable for agricultural machinery, and the minimum order quantity is 300 sets. Please feel free to contact us if you have any inquiries. 【Case Overview】 ■ Material: SCM ■ Application: Agricultural machinery ■ Manufacturing Process: Hot forging + race processing + broaching + carburizing heat treatment ■ Available Size: Up to Φ220 ■ Minimum Order Quantity: 300 sets and above ■ Features: Gears are finished only by hot forging *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the finished product "Bevel Gear" that we handled. The material is SCM415, and the application is for agricultural machinery parts. The manufacturing process includes hot forging + race processing + broaching + carburizing. We use a method called "forging" to primarily produce parts that require relatively high strength for automobiles and industrial machinery. Please feel free to contact us when you need our services. 【Case Overview】 ■Product Name: Bevel Gear ■Material: SCM415 ■Application: Agricultural Machinery Parts ■Manufacturing Process: Hot Forging + Race Processing + Broaching + Carburizing ■Orderable Lot: 200 and up *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the finished product "Bevel Gear & Shaft Gear" that we handled. The application is for agricultural machinery parts, with a minimum order lot of 100 sets. The manufacturing process includes hot forging + cold forging (for the spline part) + race processing + carburizing. Please feel free to contact us when you need our services. 【Case Overview】 ■Material: SCM415 ■Application: Agricultural machinery parts ■Manufacturing Process: Hot forging + cold forging (for the spline part) + race processing + carburizing ■Minimum Order Lot: 100 sets and up ■Features: Capable of processing long shafts *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the finished product "Bevel Gear & Pinion Gear" that we handled. The material is SCM420H, and the application is for agricultural special vehicle parts. The manufacturing process includes hot forging + warm sizing forging + race processing + carburizing + LAP processing. We provide a seamless service from mold design and manufacturing to mass production. We can produce high value-added products born from improvements in small lots. 【Case Overview】 ■ Product Name: Bevel Gear & Pinion Gear ■ Material: SCM420H ■ Application: Agricultural special vehicle parts ■ Manufacturing Process: Hot forging + warm sizing forging + race processing + carburizing + LAP processing ■ Orderable Lot: From 100 sets ■ Features: Hypoid gear *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the semi-finished product "Yoke Plate" that we handled. The material is SUJ2, and its application is for a variable mechanism of valve timing. The manufacturing process involves hot forging followed by cold sizing. The minimum order quantity is 100 or more. We provide a seamless process from mold design and manufacturing to mass production. High value-added products generated from improvements can be produced in small lots. 【Features】 ■Product Name: Yoke Plate ■Material: SUJ2 ■Application: Variable mechanism of valve timing ■Manufacturing Process: Hot forging → Cold sizing ■Minimum Order Quantity: 100 or more ■Feature: Parts that require machining are formed by forging to reduce costs. *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the semi-finished product "Hollow Valve" that we handled. The material is Inconel (heat-resistant steel), and its application is in automotive parts. The manufacturable size ranges from flange diameter φ30 to φ50. We provide a seamless process from mold design and production to mass production. High value-added products generated from improvements can be produced in small lots. 【Case Overview (Partial)】 ■Product Name: Hollow Valve ■Material: Inconel (heat-resistant steel) ■Application: Automotive parts ■Manufacturing Process: Hot forging + Cold forming ■Manufacturable Size: Flange diameter φ30 to φ50 *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the semi-finished product "reduction plate" that we handled. The material is SUJ, and the manufacturing process involves hot forging and cold forging. The application is for speed reducers, and the possible manufacturing size is up to φ200. Short-term processes lead to cost advantages, meeting the expectations of many customers. Please feel free to contact us when you need our services. 【Case Overview (Partial)】 ■Product Name: Reduction Plate ■Material: SUJ ■Application: Speed Reducer ■Manufacturing Process: Hot Forging + Cold Forging ■Possible Manufacturing Size: Up to φ200 *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the semi-finished product "Bevel Gear" that we handled. The material is S45C, and its application is in the lifting mechanism of volleyball net posts. The manufacturing process is hot forging, and the minimum order quantity is 1000 units. We develop and manufacture forged parts across various fields, not just for vehicles. Please feel free to contact us when you need assistance. 【Case Overview】 ■ Product Name: Bevel Gear ■ Material: S45C ■ Application: Lifting mechanism of volleyball net posts ■ Manufacturing Process: Hot Forging ■ Minimum Order Quantity: 1000 units ■ Features: Cost reduction through forging due to rising costs of gear cutting processing *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the semi-finished product "Shaft Gear (integrated type)" that we handled. The material is S45C, and the manufacturing process involves hot forging + cold forging + race processing. The application is for agricultural machinery (tractors), and the minimum order quantity is 100 or more. Please feel free to contact us when placing an order. 【Case Overview】 ■ Product Name: Shaft Gear (integrated type) ■ Material: S45C ■ Application: Agricultural machinery (tractors) ■ Manufacturing Process: Hot forging + cold forging + race processing ■ Minimum Order Quantity: 100 or more ■ Features: Developed by integrating four components *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the forged product "Rotor" that we have handled. The material is SCM grade 4, and the application is for motorcycle parts. The manufacturing process is hot forging. The possible manufacturing sizes are Φ100 to Φ193, weighing between 0.94kg and 6.2kg. We achieve cost reduction through years of accumulated experience and precision forging technology. Please feel free to contact us when you need our services. 【Case Overview (Partial)】 ■Product Name: Rotor ■Material: SCM grade 4 ■Application: Motorcycle parts ■Manufacturing Process: Hot forging ■Possible Manufacturing Sizes: Φ100 to Φ193, 0.94kg to 6.2kg *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the forged product "Pinion Gear" that we handled. The manufacturing process is hot forging, and the application is for automotive parts. The material is SCM grade 4, and the producible size ranges from 1.5 kg to 4 kg. We provide a seamless process from mold design and production to mass production. We can produce high value-added products generated from improvements in small lots. 【Case Overview (Partial)】 ■Product Name: Pinion Gear ■Material: SCM grade 4 ■Application: Automotive parts ■Manufacturing Process: Hot forging ■Producible Size: 1.5 kg to 4 kg *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the forged product "Gear Idle" that we handled. The application is for truck parts, and the manufacturing process is hot forging. The material used is SCM, and the possible manufacturing size is up to φ230. We develop and manufacture forged parts not only for vehicles but also for various fields. Please feel free to contact us when you need assistance. 【Case Overview】 ■ Product Name: Gear Idle ■ Material: SCM ■ Application: Truck Parts ■ Manufacturing Process: Hot Forging ■ Possible Manufacturing Size: Up to φ230 ■ Orderable Lot: 500 or more *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the forged product "Axle Housing" that we handled. Material: SCM. Maximum manufacturing size: Φ135. Manufacturing process: Hot forging, and the application is for automotive parts. Our work focuses on how to manufacture commercial parts with high quality and cost advantages through precision forging technology, ensuring stable supply. 【Case Overview】 ■Product Name: Axle Housing ■Material: SCM ■Application: Automotive parts ■Manufacturing Process: Hot forging ■Maximum Manufacturing Size: Φ135 ■Order Lot: 500 or more *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the forged product "flange" that we handled. The material is SCM or SCR, and the application is for reduction gear components. The manufacturing process is hot forging. The possible manufacturing sizes range from Φ100 to Φ180, with orderable lots starting from 300. Short lead times lead to cost advantages, meeting the expectations of many customers. Please feel free to contact us when placing an order. 【Case Overview (Partial)】 ■Product Name: Flange ■Material: SCM or SCR ■Application: Reduction gear components ■Manufacturing Process: Hot forging ■Possible Manufacturing Sizes: Φ100 to Φ180 *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of the forged product "Hypoid Gear" that we have handled. The materials range from SCM grade 4 to grade 9. The sizes we can manufacture are from Φ170 to Φ320. Additionally, the manufacturing process involves hot forging plus rolling forming. We develop and manufacture forged components not only for vehicles but also for various fields. Please feel free to contact us when you need assistance. 【Case Overview (Partial)】 ■Product Name: Hypoid Gear ■Material: SCM grade 4 to grade 9 ■Application: Drive system components ■Manufacturing Process: Hot forging + rolling forming ■Manufacturable Sizes: Φ170 to Φ320 *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of a major automobile manufacturer. We received a request for a quote from a customer considering cost reduction for precision gears in automobiles. However, due to the need for a change permit from the Land Transport Bureau, the delivery deadline for the prototype was within three months. In order to meet the customer's standards and discuss the drawings before delivery, we dedicated ourselves to the project for three months and successfully met the deadline. [Case Overview] ■Challenges - Cost reduction for precision gears in automobiles - Delivery deadline of three months ■Results - Met the three-month delivery deadline *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of a solution for our customers in the industrial machinery sector. The "curved plate," used in the heart components of gear reducers, was previously processed by cutting round bars and undergoing various machining processes. We received an inquiry asking if we could reduce costs through process reduction. By supplying a processing-free forged shaped material, we were able to reduce the number of processes by about half, resulting in cost savings. 【Case Overview (Partial)】 ■ Conventional Process - Cutting round bars (annealed material) → Raceway machining, planetary hole processing (including both sides) → Gear cutting → Hardening ■ Improved Process - Hot forging of gears → Annealing → Full hole blanking → Hardening *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of a customer who is customizing special vehicles. The product originally consisted of four parts, making procurement and assembly quite challenging, with a lot of waste. We received an inquiry asking, "Is there any way to forge this all at once?" As a result, what used to require orders from four different suppliers can now be handled by just one, and it can be procured as a single integrated unit. This has significantly reduced both labor and costs, and has also enabled stable supply. The customer was very pleased. 【Case Overview (Partial)】 ■ Product Name: Shaft Gear (Integrated Type) ■ Material: S45C ■ Application: Agricultural Equipment (Tractor) ■ Manufacturing Process: Hot Forging + Cold Forging + Race Processing *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of a customer engaged in agricultural machinery manufacturing. They consulted us, saying, "The length of the shaft is unusually long, so it would be very expensive with other companies. Is there any way we can manufacture it at a lower cost?" Since the delivery date was six months later, we quickly shifted our perspective and were able to meet the deadline. 【Case Overview (Partial)】 ■Product Name: Bevel Gear & Pinion Gear ■Material: SCM415 ■Application: Agricultural Equipment Parts ■Manufacturing Process: Hot Forging + Cold Forging (Spline Section) + Race Processing + Carburizing *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case study of a customer who has customized special vehicles for transportation at event venues and leisure facilities. They were unable to procure parts, making planned production impossible. Although they had the physical items, they were in a state where there were not even any drawings. We created the drawings, and within four months of the request, we presented the first product based on those drawings. It took about six months until mass production. They were pleased to find that they could now procure parts stably and produce with peace of mind. 【Case Overview (Partial)】 ■Product Name: Bevel Gear & Pinion Gear ■Material: SCM420H ■Application: Parts for special agricultural vehicles ■Manufacturing Process: Hot forging + Warm sizing forging + Race processing + Carburizing + LAP processing *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce Arai Industrial Co., Ltd.'s "Technology." We have a history of constantly thinking about what can be achieved through forging to "solve our customers' problems," which has led to the cultivation of our unique technological capabilities. How can we manufacture commercial parts with high quality and cost advantages? How can we achieve this in a short process and with speed? Our focus on these aspects across the entire company has contributed to our current strengths. 【Features】 ■ Even without drawings, if there is a physical sample (even if it does not retain the original form), we can design and manufacture. ■ We provide a consistent in-house response from proposal design, mold manufacturing, prototype production to mass production. ■ While being forged, we can achieve forging shapes that are close to the casting domain. *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

Our company develops and manufactures not only vehicle components but also forged parts across various fields. To "solve our customers' problems," we constantly consider what can be achieved through forging, and as a result, we have cultivated unique technical capabilities. In addition to forging, we also handle heat treatment, machining, and inspection in-house, allowing us to provide a seamless proposal from mold design and production to mass production. ▼ Examples of problems we have solved: - "I can no longer obtain the item." The physical item exists, but there are no drawings. - The shaft length is unusually long, making it very expensive with other companies. Can we manufacture it at a lower cost somehow? - Can we forge a product that originally consisted of four parts all at once? - Can we reduce costs by cutting down on processes? - Is it possible to reduce costs and prototype precision gears for automobiles? The examples listed are just a small part, but our company has numerous development cases backed by a strong desire to "try" and advanced technology. For more details on our case studies, please check the link below. *For additional details, please download the PDF document or feel free to contact us.

• Contract manufacturing

Arai Kogyo Co., Ltd. is a company that manufactures forged products and metal structural components. Utilizing our refined forging technology, we design and manufacture die-forged products used in vehicles and other applications. From small lot production to mass production, please leave the resolution of your current challenges to us. 【Products】 ■ Automotive parts ■ Industrial machinery components ■ Mold design, forging, heat treatment, and machining of bearing components *For more details, please download the PDF or feel free to contact us.

• Drive system parts