水野鉄工所 Product Lineup

Unlike prototype manufacturers that only process prototypes, our company can collaborate with customers to develop products together. By participating from the planning and conceptual stage with process design that achieves suitable dimensional accuracy and product costs in anticipation of mass production processes, we realize low-cost prototype development. Additionally, in analysis and simulation, we combine CAE/CAM to enable simulations that are close to actual processing. 【Features】 ■ Early detection and improvement of various issues that could lead to cost increases ■ Ability to respond to sudden design changes through consistent data management ■ Utilization of dedicated prototype machines allows for quick responses to various shaped parts ■ Low-cost prototype development is possible by participating from the planning and conceptual stage ■ Process design that achieves suitable dimensional accuracy and product costs in anticipation of mass production processes ■ Combining CAE/CAM enables simulations that are close to actual processing *For more details, please download the PDF or feel free to contact us.

"MBD (Model-Based Design)" refers to a development approach that incorporates pre-evaluation using simulation models such as CAE. Our company realizes MBD (Model-Based Design) for plastic processing by analyzing the distribution of compressive stress due to die reinforcement, the degree of die deformation during molding, and the accumulation of plastic deformation data. With a VA/VE strategy utilizing MBD (Model-Based Design), we solve existing issues and provide value to our customers. 【Features】 ■ Understandable without trying ■ Insights into residual stress and work hardening after processing ■ Mold improvement: relying on calculations and numerical data ■ Ability to present optimal solutions based on numerical data *For more details, please download the PDF or feel free to contact us.

Our company can propose cost reduction utilizing aluminum extrusions. By replacing the current method of punching from sheet material with a new method of cutting from extrusions, we achieve cost reductions through improved yield and reduced processing time. We have obtained benefits in terms of weight comparison, yield comparison, fuel efficiency comparison, CO2 emissions, and more, making a total cost reduction of 15-25% possible. 【Comparison Data】 ■ Weight Comparison: The products from the new method achieve approximately 65% weight reduction. ■ Yield Comparison: The new method improves yield by approximately 35%. ■ Fuel Efficiency Comparison: An improvement of about 4 meters per liter is expected. ■ CO2 Emissions: The new manufacturing method reduces emissions by approximately 20%. *For more details, please download the PDF or feel free to contact us.

We would like to introduce an example of our contribution to ADAS functions utilizing aluminum cold forging technology. In the case of producing a heat-dissipating camera case using irregular cold forging technology, we used aluminum materials with high thermal conductivity to quickly dissipate internal heat buildup. Additionally, the uneven surface on the back was reproduced with the unique protrusion shape characteristic of forging technology, which helps reduce machining costs. We also have examples of components for clearance sonar using A6061. 【Case Overview】 ■ Aluminum Camera Case - High heat dissipation, reproduction of uneven surface on the back ■ Clearance Sonar Components - Material: A6061 - Manufacturing Method: Cold Forging + Cutting Near-Net Shape *For more details, please download the PDF or feel free to contact us.

We offer processing of stainless steel (cutting/grinding/cold forging). Our cutting processing achievements include knurling of SUS303/SUS304/SUS316/SUS420J2, external gear processing, internal keyway processing, internal mirror finishing, and internal hex hole processing. We also have achievements in cold forging processing of SUSXM7/SUS430MT. Mold design and layout design are done in-house, allowing for a speedy response. We verify suitable processing methods in advance through simulations. 【Examples of Achievements】 ■ Cutting Processing Achievements - SUS303/SUS304/SUS316/SUS420J2 - Knurling/external gear/internal keyway/internal mirror finishing/internal hex hole processing ■ Cold Forging Processing Achievements - SUSXM7/SUS430MT *For more details, please download the PDF or feel free to contact us.

Our company can achieve a balance of speed and cost with centerless grinding. Centerless grinding is a process that uses a high-speed rotating grinding wheel to remove material from the surface of a workpiece. It is a grinding machine that grinds the outer diameter of cylindrical workpieces. There are two types: through grinding and in-feed grinding. The advantages of processing cylindrical grinding products with centerless grinding include reduced cycle time (lower processing costs) and suitability for mass production (increased productivity). 【Features of Centerless Grinding】 ■ Setup: Easy and fast ■ Precision: Inferior to cylindrical grinding ■ Processing Speed: High-speed processing ■ Product Characteristics: Only cylindrical shapes ■ Technology: Requires skill *For more details, please download the PDF or feel free to contact us.

We would like to introduce our company’s uniform chamfering process for cylindrical shapes with lateral holes. When processing chamfers on products with a cylindrical shape, conventional chamfering often results in an elongated hole shape (oval). For products where the finished diameter is specified for functional reasons, uniform chamfering width becomes necessary. Our company utilizes 3D chamfering technology, allowing for uniform chamfering within NC lathes. The 3D chamfering process can accommodate any hole diameter (outer or inner diameter). 【Features】 - Application of machining center processing technology - Capable of uniform chamfering - Can accommodate any hole diameter (outer or inner diameter) - Uniform chamfering possible within NC lathes *For more details, please download the PDF or feel free to contact us.

We would like to introduce our cold forging technology for small precision parts. In the case of cold forging of aluminum materials with irregular shapes, we achieved consistent shaping from round wire (coil material) using a former. By cold forging from a round cross-section to a diamond shape, we reduced material costs by approximately 55% and product costs by 55%. Additionally, we also accommodate cold forging of thin-walled products (thickness of 1.35mm). This resulted in improved productivity and a 35% reduction in product costs. [Case Summary] ■ Challenges - Irregular materials have high material costs - In machining, hole processing becomes a separate process, leading to poor yield ■ Results - Cold forging from round cross-section to diamond shape - Material costs reduced by approximately 55% / Product costs reduced from 100 to 45 (55% reduction) *For more details, please download the PDF or feel free to contact us.

We would like to introduce the processing technology for SUS316 material in response to the hydrogen society. In the regulations related to "Handling of Hydrogen Gas & Liquid Hydrogen" updated in 2019, SUS316 has been specified as the material for parts that come into contact with hydrogen. As we transition to a hydrogen society, particularly with fuel cell vehicles (FCVs) and hydrogen engines, an increase in demand for SUS316 is expected. Our company has various examples of machining processes for SUS316 material. Please feel free to consult us when needed. 【Examples of vehicle components requiring SUS316】 ■ Hydrogen tanks ■ Inlet ports ■ Piping ■ Nozzles ■ Valves ■ Engine internals (explosion areas) *For more details, please download the PDF or feel free to contact us.

We would like to introduce our cold forging technology. We can accommodate ring shapes with thin wall finishes (approximately 1mm thick). Both end faces of the ring can be beveled, and the outer diameter precision is within ±0.1mm. Additionally, we achieve increased strength through cold forging. The surface is also smooth, eliminating the need for finishing processes. Our unique processing technology allows multiple processes to be performed simultaneously, enabling space-saving and highly efficient production. 【Features】 ■ Up to three processes can be completed in one operation ■ Capable of handling precise and complex shapes ■ High-precision and high-strength processing that utilizes the material ■ Outstanding productivity and cost competitiveness ■ Well-equipped production facilities ■ Reliable quality assurance with 100% inspection *For more details, please download the PDF or feel free to contact us.

We would like to introduce our efforts towards unmanned operation and the abolition of full inspection in the cutting process. After progressing through the first generation of conventional methods and vertical methods, the second generation of intermittent cutting, and the third generation of vibration cutting, internal lubrication holders, and high-pressure coolant, the fourth generation improves processing time and chip handling by combining the features of the first, second, and third generations. We aim to achieve improvements in frequent stoppages, chip wrapping, and poor engagement, as well as reductions in cycle time (CT) while balancing CT reduction with countermeasures for defects. 【Features】 ■ Improvement of frequent stoppages, chip wrapping, and poor engagement ■ Reduction in cycle time (CT) ■ Balancing CT reduction with countermeasures for defects *For more details, please download the PDF or feel free to contact us.

We would like to introduce our cold forging of parts with flanges on both ends. Parts with flanges on both ends cannot be formed using standard cold forging molds, and the undercut areas require machining, which presents a challenge. At our company, we use split molds during cold forging to solve this problem. By leveraging our expertise in process combination technology, we propose the optimal method and achieve cost reduction for the products. [Our Method] ■ Coil Material ■ Former ■ Knurling ■ Annealing & Bonding ■ Cold Forging Press (Split Mold) *Machining possible without cutting *For more details, please download the PDF or feel free to contact us.