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This document introduces the technology of cold forged products at Ibaraki Steel Center Co., Ltd. It includes examples of cold forging, such as cold forging from inner diameter scrap, examples of process reduction utilizing work hardening through forging, and examples of long hole processing within the pressing process, along with images of cold forging from blank products. It also presents achievable major dimensional accuracies, making it easy to reference. Please feel free to download and take a look. [Contents] ■ Thick plate blanking processing ⇒ Cold forging examples ■ Cold forging from inner diameter scrap ■ Cold forging from blank products ■ ISC cold forging technology ■ Materials handled ■ Achievable major dimensional accuracies *For more details, please download the PDF or feel free to contact us.

• Processing Contract

The customer needed to manage multiple outsourcing tasks and was facing challenges. Our company completes everything from materials to forging within a single factory. We can also handle each process individually. As a result, we have demonstrated the effectiveness of quality control and significant cost advantages, receiving positive feedback from our customers. 【Case Summary】 ■ Issue: Need to manage multiple outsourcing tasks ■ Solution: Complete everything from materials to forging within a single factory ■ Effect: Quality control and significant cost advantages *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

The customer was struggling with whether to create molds for prototypes based on different conditions or to prepare them using full machining, which would require a lot of money and time, as part of the pre-mass production stage. Therefore, we proposed the production of prototype workpieces from stock materials. Using a 6kw laser, we provided prototype workpieces (a small number of various types with a 1mm difference) immediately. As a result, we were able to reduce the costs of prototype molds and lead times. 【Case Summary】 ■Issue: Struggling with prototyping as a pre-mass production stage ■Solution: Produced prototype workpieces from stock materials using a 6kw laser ■Effect: Reduced costs of prototype molds and lead times *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

The customer was troubled by the costs incurred from the working time due to full cutting. Therefore, we proposed a near-net shape unique to ultra-precision cold forging. We achieved high precision and eliminated partial cutting in the cold forging process. As a result, we were able to find a reduction in total costs for products that can be handled by cold forging. 【Case Summary】 ■Issue: Working time from full cutting = Cost ■Solution: Near-net shape unique to ultra-precision cold forging ■Effect: Found a reduction in total costs *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

The customer was troubled by distortion caused by heat treatment. Therefore, we proposed the abolition of heat treatment and a switch from hot forging to cold forging. As a result, they were freed from the need for full inspection due to heat treatment distortion. 【Case Summary】 ■Issue: Distortion due to heat treatment ■Solution: Abolition of heat treatment and switch from hot forging to cold forging ■Effect: Freed from full inspection due to heat treatment distortion *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

The customer was troubled by excessive processes, costs, and the effort required for corrections due to core runout caused by the two-part configuration. Therefore, we proposed the integration of the two parts using work hardening through cold forging. As a result, we achieved multiple improvements, including reductions in cost, weight, elimination of heat treatment, process reduction, and the elimination of correction work due to excellent concentricity. 【Case Overview】 ■ Issue: Excessive processes, costs, and effort for corrections due to core runout caused by the two-part configuration. ■ Solution: Integration of the two parts using work hardening through cold forging. ■ Effects: Achieved multiple improvements such as reductions in cost, weight, elimination of heat treatment, process reduction, and elimination of correction work due to excellent concentricity. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

The customer was struggling with significant work time and costs arising from processing multiple holes. Our forging press achieves the processing of closely spaced multiple holes in a single stroke. As a result, we were able to produce multiple holes with high quality in the forging process, significantly reducing work time and leading to substantial cost reductions. 【Case Summary】 ■ Issue: Significant work time and costs incurred in processing multiple holes ■ Solution: Achieved processing of closely spaced multiple holes in a single stroke with a forging press ■ Effects: - Produced multiple holes with high quality in the forging process - Significantly reduced work time and achieved substantial cost reductions *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

Are you concerned about the rising material costs and cutting costs that affect product costs due to global material price increases? Our company can reduce cutting costs and input material costs by decreasing the volume of materials used through our unique cold forging technology, which allows for quality shape changes within a single stroke. By improving material yield through forging shape changes, we can reduce both material costs and cutting costs (shortening cutting time). 【Overview】 ■ Issue: Material costs and cutting costs in product costs ■ Solution: Improvement of material yield through forging shape changes ■ Effects: Approximately 15% increase in material yield Reduction in both material costs and cutting costs (shortening cutting time) *For more details, please request materials or view the PDF data available for download.

• Processing Contract
• Contract manufacturing

The customer was facing issues with cost, quality, and production capacity due to the use of multiple presses for production. Therefore, we proposed completing the forged products in one stroke using our AIDA UL2000 ton press. By feeding the material into the press entrance, the finished products can be discharged from the press exit, allowing for improvements in quality (including slit holes and engraving processes), cost, and lead time. 【Case Overview】 ■Challenge: Production using multiple presses led to issues with cost, quality, and production capacity. ■Solution: Completion using the AIDA UL2000 ton press. ■Effect: Improvements were achieved in quality, cost, and lead time. *For more details, please refer to the PDF document or feel free to contact us.

• Press Dies
• Processing Contract
• Contract manufacturing

This catalog is a collection of case studies aimed at customers facing management and cost challenges related to multi-process (using multiple presses). It includes topics such as "integration of multiple parts," "part distortion due to heat treatment processes," and "outsourcing management of multiple processes." We have also received positive feedback regarding quality control and significant cost benefits. We encourage you to take a look. 【Contents】 ■ Issue 1: <Multiple press processes for a single product> ■ Issue 2: <Material costs and machining costs as a percentage of product cost> ■ Issue 3: <Work time and cost issues for processing multiple holes> ■ Issue 4: <Integration of multiple parts> ■ Issue 5: <Part distortion due to heat treatment processes> ■ Issue 6: <Machining time> ■ Issue 7: <Lead time and cost for prototype creation> ■ Issue 8: <Outsourcing management of multiple processes> *For more details, please refer to the PDF document or feel free to contact us.

• Press Dies

This document provides a thorough explanation of the basics of cold forging, including cost reduction examples and cost estimates. Cold forging is a processing method that shapes metallic materials such as carbon steel, non-ferrous metals, and alloy steel using molds at room temperature, which is below the recrystallization temperature. We will introduce various measures to address the disadvantages of cold forging and key points for cost reduction. We encourage you to read it. 【Contents】 ■ What is cold forging ■ Advantages and disadvantages of cold forging ■ Measures for the disadvantages of cold forging at our company ■ Cost reduction point (1) – Introduction of a 2000-ton press machine ■ Cost reduction point (2) – High technical capabilities *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company, which consistently manufactures thick plate press products from material procurement, is offering a free booklet titled "Basic Knowledge on Thick Plate Cold Forging" that condenses explanations and knowledge about "cold forging processing." - What exactly is "cold forging" and what does that process entail...? - I can't explain the difference between "cold forging" and "hot forging"... - I'm curious about what kind of machines are used in thick plate press equipment... We provide comprehensive explanations using technical information, photos, and illustrations to address these inquiries! Additionally, we have included examples of "cold forging products" such as rotors for generators and Mag pulleys for car air conditioners. We encourage you to read and utilize this information! [Contents Included] ■ ISC Thick Plate Processing Manufacturing Process ■ What is Cold Forging? ■ Differences Between Cold Forging and Hot Forging ■ Introduction to Cold Forging Equipment ■ Examples of Cold Forging Implementation *For more details, please refer to the PDF document or feel free to contact us.

• Engine parts

The "Bonded Processing Equipment" is a device that applies a lubricating film to eliminate friction resistance between the molded products and the molding dies during cold forging processing. By using a rotary drum system, it achieves an unmanned integrated line for washing, degreasing, shot blasting, rinsing, chemical film treatment, and lubricating film treatment. The drum system makes it easy to manage chemical concentrations, and it results in less chemical degradation and a uniform film. 【Features】 ■ Realizes an unmanned integrated line using a rotary drum system ■ Easy management of chemical concentrations ■ Less chemical degradation and a uniform film is obtained *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Ibaraki Steel Center Co., Ltd. performs shearing cutting. We can accommodate thicknesses up to 25mm and carry out width cutting of blanking materials, as well as cutting of large and small products. Our company is equipped with facilities that can perform cutting according to customer needs, such as the "25mm shearing machine with NC robot feeding device" and the "14mm shearing machine." [Features] ■ Capable of handling thicknesses up to 25mm ■ Cutting available according to customer needs *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Ibaraki Steel Center Co., Ltd. performs blanking processing. We can accommodate thicknesses up to 16mm. With progressive multi-row punching, we can achieve efficient and high-yield thick plate blanking processing. We have the "ULM 1000-ton blanking press" and the "1200-ton blanking press" that can handle plate thicknesses from 8.0mm to 16.0mm. 【Features】 ■ Accommodates thicknesses up to 16mm ■ Efficient and high-yield thick plate blanking processing through progressive multi-row punching *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Ibaraki Steel Center Co., Ltd. conducts high-frequency partial annealing. Processing hardening appears on the cut section after blanking, which can cause cracking during cold forging. The "high-frequency annealing device" performs partial annealing to prevent such cracking. It can heat to 723°C in a 3-second cycle, reducing heating costs compared to conventional full annealing furnace inputs and preventing degradation of the base material's strength. We have obtained a patent for the "method of relieving stress distortion and processing hardening of clutch and rotor blanks." 【Features】 ■ Reduction of heating costs ■ Prevention of degradation of base material strength ■ Patent obtained *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company performs gas cutting and laser cutting. In the cutting department, we handle thick and medium plates for components such as heavy electrical equipment (generators, transformers, circuit breakers), nuclear equipment, and building systems (elevators, escalators). We aim to achieve short delivery times by increasing yield and efficiency through full CAD nesting and common cutting, and we have realized three-dimensional rectangular bevel processing using our self-developed 3D gas NC beveling robot. Additionally, we respond to requests using cutting beveling machines with minimal thermal impact and portable beveling machines that can be used anywhere. 【Features】 ■ High-precision thick and medium plate cutting processing with short delivery times ■ Achieving short delivery times through increased yield and efficiency with full CAD nesting and common cutting ■ Realization of three-dimensional rectangular bevel processing using our self-developed 3D gas NC beveling robot *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Ibaraki Steel Center Co., Ltd. conducts cold forging processing. By utilizing mold design technology that maximizes the performance of UL presses, we are capable of developing cold forged products that closely resemble the shape and precision of the final product, as well as integrating products composed of multiple parts. We achieve cost reductions through the reduction of cutting processes, improvement of material yield, and the elimination of quenching treatment processes by utilizing the work hardening properties of cold forged products, all while realizing environmentally friendly manufacturing. [Features] ■ Reduction of cutting processes ■ Improvement of material yield ■ Cost reduction possible *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

"Cold forging" refers to the processing of metallic materials such as carbon steel, non-ferrous metals, and alloy steel, formed at room temperature, which is below the recrystallization temperature, using molds. By controlling the flow of the internal structure of the material (plastic flow), it is possible to obtain high precision and high strength shapes that are equivalent to or similar to the desired processing shape (net shape). As a result, resource-saving and environmentally conscious manufacturing can be achieved, such as reducing secondary processes. [Types of Cold Forging Processing (Partial)] ■ (Forward/Backward) Extrusion Molding ■ Upsetting Molding ■ Punching Processing ■ Drawing Processing ■ Shaping Processing *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

We would like to introduce our cold forging equipment, the "UL-2000 Ton Press Machine." This machine was introduced with the aim of maximizing the performance of the UL press and developing and mass-producing cold forged products that are as close as possible to the shape and precision of the final product. With features such as a frame structure with high rigidity and a long equipment lifespan, it enables stable manufacturing of high-quality and high-precision products. 【Features】 ■ High precision straightness with "zero" gap sliding ■ The press machine body has a frame structure with high rigidity ■ The body is compact in relation to the load ■ Overall high machine precision and rigidity result in an extremely long equipment lifespan *For more details, please refer to the PDF document or feel free to contact us.

• Casting Machine

We would like to introduce our "Thick Plate Processing Manufacturing Process." Our company collaborates with material manufacturers to research materials suitable for thick plate cold forging processing, providing materials that do not crack and have good elongation properties. We also possess equipment such as the "High-Frequency Partial Annealing Device," which can perform partial annealing treatment, and the "Shot Bonding Treatment Device," which enables unmanned integrated line manufacturing. 【Manufacturing Process】 ■ Blanking Processing ■ High-Frequency Partial Annealing ■ Shot Bonding Processing ■ Cold Forging Forming Processing *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce the "rotor for generators" that we have processed. Our company has achieved integrated mass production from material to shaping in-house. In cold forging processing, we guarantee strength equivalent to or greater than that of heat-treated products due to work hardening. We have successfully reduced costs through significant process reductions, resource conservation, and energy savings. 【Manufacturing Process】 ■ Material: SAE1018 steel plate ■ Blank ■ Shot bonding ■ Cold forging processing ■ Finishing ■ Completion *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce the "Industrial Machine Parts" that we have processed. The "Pulse Plate for Outboard Motors" is a component that is attached to the end of the crankshaft of an outboard motor and detects the ignition timing based on the angle of the engine's cylinder. The boss section and plate section are formed as a single unit. Additionally, the "key" that engages with the crankshaft is also integrally formed. 【Product Specifications】 ■ Pulse Plate for Outboard Motors - Material: SPHC Steel Plate - Size: Outer diameter φ103 × L45mm *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce our processed "blank products." The "blanks for rotor cores" with a thickness of 9-12mm can undergo shot peening and bonding treatment in the next process. The "blanks for car air conditioning pulleys" with a thickness of 8-14mm can undergo inner diameter annealing followed by shot peening and bonding treatment in the next process. Additionally, they can be manufactured at a rate of approximately 100 pieces per minute through progressive multi-column punching. 【Product Specifications】 ■ Blanks for rotor cores - Material: SPHC (steel plate) - Thickness: 9-12mm - Outer diameter: φ100-φ140 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce the "Mag Pulley for Car Air Conditioning" that we have processed. For cold forging processing of pulleys by other companies, one press is required for each process when multiple processes are involved. In our case, since we use UL presses, we can arrange multiple processes within a single press, allowing for forging in one punch (shot). Additionally, we have developed the "Flanged Mag Pulley" aimed at improving yield. 【Product Specifications】 ■ Material: SPHC Steel Plate ■ SIZE: Outer Diameter Φ120×L40mm *For more details, please refer to the PDF document or feel free to contact us.

• Belts and pulleys

We would like to introduce our processed product, the "Mag Pulley Slit Punching." We have achieved simultaneous inner and outer punching in one process, regardless of the number of slits. Processing can be done without any abnormalities such as burrs or secondary shearing. Additionally, we have cleared a significant processing ratio for slit width relative to plate thickness. 【Features】 ■ Achieved simultaneous inner and outer punching in one process, regardless of the number of slits ■ Processing possible without abnormalities such as burrs or secondary shearing ■ Cleared a significant processing ratio for slit width relative to plate thickness (3.3 times processing ratio) *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

We would like to introduce an example of our cold forging and forming process. The "Carrier Plate for AT" is a component that is incorporated inside the AT and is responsible for holding the planetary gears. Our company has achieved the difficult processing of complex-shaped products like this component by utilizing mold design technology and cushioning devices. Additionally, we are capable of high processing rates for medium carbon steel. 【Features of Our Cold Forging Process】 ■ Difficult processing of complex-shaped products is realized ■ High processing rates for medium carbon steel are achieved ■ Processing rate for leg extrusion: 70% to 80% ■ Flatness of the intermediate surface of the leg: 0.05mm or less *For more details, please refer to the PDF document or feel free to contact us.

• Career

We would like to introduce our examples of cold forging and shaping. The "piston for AT clutches" is a piston used to switch the clutch ON/OFF via hydraulic pressure. It is the spring seat required to release the piston when it is in the OFF position. Our spring seat shaping process involves arranging the press molds according to the number of spring seat holes and performing the shaping in one stroke with a single punch. 【Product Specifications】 ■ Material: SAE1020 steel plate (equivalent to S25C) ■ SIZE: Outer diameter Φ130 × L25mm *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

This document outlines the differences between cold forging and hot forging processes. We present the advantages and disadvantages of each processing method in an easy-to-understand table. Our cold forging process compensates for its disadvantages through technology, equipment, and experience, enabling us to achieve high processing accuracy, which allows for a reduction in subsequent processes and cost savings. [Contents] ■ Advantages and disadvantages of cold forging ■ Advantages and disadvantages of hot forging *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

This technical document provides a cost image for high-precision cold-forged rotor materials. We present a table of product sizes (φmm) and costs (yen/piece). Our company is capable of providing high-precision cold-forged materials. Additionally, we can consider forged products with irregular or complex shapes, so please feel free to contact us. 【Contents】 ■ Cold Forged Material Cost Map *For more details, please refer to the PDF document or feel free to contact us.*

• Processing Contract

Our company utilizes mold design technology that maximizes the performance of UL press machines to carry out thick plate cold forging processing. We are capable of developing cold forged products that are extremely close to the shape and precision of the final product, as well as integrating products composed of multiple parts. 【Processes】 ■ Thick plate blanking processing ■ High-frequency partial heat treatment ■ Shot bonding treatment ■ Cold forging processing *For more details, please download the PDF or contact us.

• Other machine elements