ヤマナカゴーキン List of Products and Services

"DEFORM" is a CAE software that can analyze various changes caused by processing in metalworking, such as the flow of metal materials and the stress state of molds during forging, cutting, and heat treatment. "Is it possible to process within the capacity of the existing press?" "Will the mold break?" "Is the desired shape achieved? Are there any unfilled areas?" "Will the forged product crack?" By predicting issues that may occur during processing in advance, it reduces the number of prototype work hours and costs. We have prepared a collection of analysis case studies for "press forming and sheet forging," so please feel free to contact us if you are interested. [Contents of the Press Forming and Sheet Forging Analysis Case Study Collection] ◎ Overview of CAE software "DEFORM" ◎ Case Study 1: Sheet Forging ◎ Case Study 2: Fracture Analysis (2D Analysis) ◎ Case Study 3: Press Forming Punching Process ◎ Case Study 4: Press Forming Burring Process ◎ Case Study 5: Press Forming Bending Process

• Other analyses

"Porosity" refers to the phenomenon where cavities form inside the material during the casting process. Porosity is a type of casting defect that negatively affects the strength and durability of the product, so it is important to prevent its occurrence in order to avoid the outflow of defective products. Our company can identify the causes of porosity by utilizing sensing technology. We will introduce a case from aluminum die casting, so if you have concerns like these, please check the related links for more details! ◎ Porosity occurs due to differences in casting machines even when produced under the same conditions. ◎ The root cause of porosity is not clearly understood. *This case study is excerpted from the IVI (Industrial Value Chain Initiative) and the activities of the Business Scenario Working Group.

• Other measurement, recording and measuring instruments

"Kasugari" refers to a phenomenon in progressive stamping or punching processes where the scrap does not fall through the die but remains on the die surface for some reason. If production continues with scrap remaining on the die surface, it can leave marks on the material, leading to the risk of defective products being released and potentially damaging the mold. Since it can have a significant impact on the entire production process, early detection of kasugari is considered extremely important. Our company can detect kasugari early by utilizing sensing technology. We will introduce a case of "detecting kasugari" in the motor core punching process, so if you have such concerns, please check the details through the related links! ◎ Existing kasugari sensors are unable to detect it, leading to the release of defective products. ◎ To prevent the release of defective products, we are conducting 100% inspection, which incurs costs.

• Other measurement, recording and measuring instruments

As a foundational technology for realizing smart factories utilizing IoT, there is an increasing expectation worldwide for the integration of sensors into everything, as well as for the big data analysis of the vast numerical information obtained and AI technologies. Our company is also working on the development of foundational technologies applicable to visualizing manufacturing processes, detecting anomalies, and maintaining equipment by utilizing sensing technology and forging simulation. This time, we will introduce a case where the piezoelectric load sensor PiezoBolt and dedicated measuring equipment were applied to cutting processes (drilling) to detect signs of tool failure. If you have concerns like these, please check the related links for more details: ◎ During processing, operators are almost constantly monitoring while listening for sounds, but defects frequently occur. ◎ The timing of tool changes varies depending on the monitoring operator. ◎ We tried using AE sensors, but it is difficult to identify signs of anomalies or pinpoint them when they occur.

• Other measurement, recording and measuring instruments

DEFORM is a CAE software that can analyze various changes caused by processing, such as the flow of metal materials and the stress state of molds in metal processing, including forging and sheet forging. By predicting issues that may occur during processing in advance, it reduces prototype labor and costs. 【Manufacturing Processes Analyzed by DEFORM】 ◎ Forging (cold, hot, warm) ◎ Sheet forging ◎ Sheet forming (press processing) ◎ Cutting ◎ Heat treatment ◎ Roll forming ◎ Extrusion ◎ Joining (riveting, welding, FSW) ◎ Metal additive manufacturing 【Features】 ◎ Diverse Analysis Functions From features that allow beginners in CAE software to easily perform analyses to functions that assist experienced users in enhancing and streamlining their analysis tasks, DEFORM is equipped with a variety of capabilities. ◎ Comprehensive Support System We not only assist with software usage but also solve problems related to plastic processing. Our dedicated staff supports customers based on the technology cultivated as a forging die manufacturer. ◎ Extensive Track Record We have been adopted by customers in various fields, including automotive, steel, aerospace, and electronics. Additionally, there are many implementations in universities and public institutions.

• Stress Analysis

Do you have concerns such as "I want to reduce the costs associated with prototyping" or "I want to shorten the lead time for product development"? These issues can be resolved by utilizing CAE analysis! This document compiles everything from the basic knowledge of CAE analysis to practical examples of its application in one book. The examples summarize the benefits of using CAE analysis for each processing method, so please take a look. 【Table of Contents】 ■ What is CAE? ■ Effects of Utilizing CAE ■ Basic Knowledge of CAE Analysis ■ Points to Note in CAE Utilization ■ Analysis Examples for Each Processing Method Cold Forging, Hot Forging, Open Die Forging, Cutting, Shearing, Heat Treatment, Riveting, Rolling *For more details, please refer to the PDF document or feel free to contact us.

• Other analyses

Our company has been supporting the digital transformation (DX) of small and medium-sized manufacturing businesses based on our know-how developed over many years, from core business systems to factory support systems utilizing IoT and sensors. We develop and provide fully customized systems tailored to the individual business flows of each company. Additionally, we have case studies of the measurement system "YMC with D-WT," which is equipped with a unique evaluation program and can handle everything from measurement to evaluation and control. 【DX Promotion Examples】 ■ System Development ■ Paperless Solutions ■ RPA Automation ■ IoT Implementation ■ Machine Visualization ■ Inspection Digitalization *For more details, please refer to the PDF document or feel free to contact us.

• Other operation management software

In general, it is said that seizure can be evaluated by combining surface pressure and speed. However, in gear molding, although it is understood that the differences in the gear's entry shape affect seizure, the surface pressure and speed show almost the same distribution, making evaluation difficult. Therefore, to consider the significantly different material surface spread due to the gear entry shape, we made the surface expansion rate a new CAE evaluation item, enabling the evaluation of seizure. Please check the related links for more details. *Detailed information about the case can be viewed through the related links. For more information, please feel free to contact us.

• simulator

Among the parts made from sheet material, those that undergo processes such as barreling, drawing, bending, and thickening often require more than 10 steps for shaping. In recent years, there has been an increase in shaping using multi-action multi-axis presses in a single step (one-shot forming). During this shaping process, defects such as cracking caused by local necking during bending or cup forming, and entrapment during the thickening process, arise due to the unpredictable flow behavior of the material. Development is carried out through repeated trial and error. In this instance, we will introduce a case where we improved product defects (entrapment) in the shaping process of dry plates using our CAE software "DEFORM." *For detailed information about the case, please refer to the related link. For further inquiries, feel free to contact us.

• simulator

In the forging process, changes in load and temperature history are measured using appropriate sensors, and by analyzing the fluctuations in measurement signals during normal operation and the variations in the acquired data signals, a technology has been developed to detect abnormalities during mass production, specifically targeting multi-stage forging processes such as those involving formers. Additionally, in recent years, research and development have intensified regarding the incorporation of sensors within molds to detect abnormalities such as product defects and mold damage in press forming. This document introduces the bolt-type piezo sensor "PiezoBolt," along with a dedicated measurement system, and various examples of process monitoring conducted using this system. *For more details, please refer to the PDF document or feel free to contact us.*

• Other security and surveillance systems

This document introduces cases where the load sensor "PiezoBolt" has been utilized to solve various challenges in production sites. It includes a total of 14 cases, such as improving the quality of machined surfaces and reducing defect rates through machine learning, detecting vibrations during cutting, and visualizing tool conditions. The monitoring results and operational methods are explained in detail according to different issues, making it a useful reference for improving productivity. 【Contents (partial)】 ■ Improving the quality of machined surfaces and reducing defect rates through machine learning ■ Detecting vibrations during cutting and visualizing tool conditions ■ Reducing downtime through automatic adjustment of blocked forged products ■ Detecting abnormalities in mold cracking and optimizing mold replacement timing! ■ Determining mold installation accuracy through "dry runs"! Reducing trial run costs *For more details, please refer to the PDF document or feel free to contact us.

• Other security and surveillance systems

In this document, we introduce examples of "remote monitoring systems." We will explain the concept of remote monitoring systems using edge computing systems, as well as the mechanisms for data transfer, processing, and sharing. We also present information on operational methods and expected benefits, so please take a moment to read through it. 【Contents】 ■Introduction ■Case Studies ■Concept ■Mechanisms for Data Transfer, Processing, and Sharing ■Operational Methods ■Expected Benefits *For more details, please refer to the PDF document or feel free to contact us.

• Other security and surveillance systems

This document introduces simulation and sensing technologies that support the improvement of the lifespan of forged molds. Efforts to enhance mold lifespan are widely conducted in design fields, but there are still few examples of initiatives that quantitatively predict and utilize the lifespan of forged molds. We will explain the evaluation technologies and initiatives for quantitative prediction based on the current situation. 【Contents】 ■ Introduction ■ Improvement of mold lifespan using forging simulation ■ Mold lifespan prediction technologies ■ Potential of sensing technologies in mold lifespan evaluation ■ Conclusion ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Other molds

This document introduces a case study on monitoring manufacturing equipment using the bolt-type piezoelectric load sensor "PiezoBolt," developed with the sensoric fastener technology proposed in Germany. It also includes efforts toward IoT implementation, explained in detail and clearly. Please take a moment to read it. 【Contents】 ■ Introduction ■ Case study on condition monitoring of press machines ■ Case study on condition monitoring of machine tools ■ Future possibilities ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Technical and Reference Books

This document introduces case studies on the use of simulations for improving the lifespan of cold forging molds, as well as examples of lifespan predictions for cold forging molds based on a fatigue failure model of cemented carbide. We encourage you to read it. 【Contents】 ■ Introduction ■ Improving Mold Lifespan Using CAE ■ Lifespan Prediction of Cold Forging Molds ■ Future Challenges ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Technical and Reference Books

This document introduces an analysis of the factors affecting die life in hot forging using CAE, as well as improvements related to it. Improving die life in hot forging offers significant benefits in both cost reduction and quality stabilization, making it a priority issue to address. We will explain the efforts to apply CAE (Computer Aided Engineering) to process evaluation and connect it to countermeasures. 【Contents】 ■ Introduction ■ Estimation of die life factors and efforts towards countermeasures ■ Case studies for improving die life ■ Conclusion ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Technical and Reference Books

This document explains the measurement of phenomena within molds using bolt-type load sensors. We will introduce measurement technologies using sensors, which are essential element technologies supporting innovations in manufacturing as automation advances, such as IoT and smart factories, as well as case studies aimed at monitoring and analyzing the forging process. We encourage you to read it. 【Contents】 ■ New developments for next-generation manufacturing ■ Visualization of processes using bolt-type piezo sensors ■ Introduction of application examples ■ New possibilities for measurement technology ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Technical and Reference Books

This document provides an overview of the numerical simulation techniques used in forging process design and examples of their applications. In advancing the design and development of processes utilizing multi-motion to achieve a variety of processing variations, technical support through numerical simulation is essential. It includes application examples related to actual forging, such as deep hole machining of shaft components and closed forging of hollow components with flanges. We encourage you to read it. [Contents] ■ Introduction ■ Prediction methods for cracking using numerical simulation ■ Application examples in actual forging ■ Conclusion ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Technical and Reference Books

This document presents the current status and challenges of developing forged automotive parts using simulation technology. It introduces case studies of CAE applications in the design of forged automotive parts, as well as the design environment for the forging process. Additionally, it explains CAE application technologies to meet the upgraded design needs. In addition to detailed explanations, it includes numerous diagrams and images, making it a useful reference. [Contents] ■ Introduction ■ Mold design support for automotive forged parts using CAE ■ Case studies ■ Conclusion ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Mold Design

This document introduces the evolution of simulation technology that has supported forging design and the future prospects of digital engineering, along with representative case studies. It explains topics such as process design support through deformation behavior prediction and lifespan improvement through die application force prediction, so please take a moment to read it. [Contents] ■ History of forging simulation ■ Process design support through deformation behavior prediction ■ Lifespan improvement through die application force prediction ■ Possibilities of process optimization and experimental design ■ Future possibilities ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Other molds

This document presents research and development examples regarding the current state of fatigue life prediction for cold forging molds. As numerical analysis techniques are increasingly utilized in companies dealing with forging processes, efforts to evaluate stress loads on forging molds and to develop methods for reducing stress loads have become more active. We provide explanations on mold life prediction using fatigue testing and stress analysis, as well as advanced analytical methods that consider the effects of carbides, so please take a moment to read it. 【Contents】 ■ Introduction ■ Techniques for predicting the fatigue life of molds ■ Research examples related to mold life prediction ■ Conclusion ■ References *For more details, please refer to the PDF document or feel free to contact us.

• Other molds

To handle cutting phenomena through simulation, it is necessary to have the material properties (deformation resistance) of the material, which significantly affects the results of CAE. The deformation resistance, a mechanical property of the material, is measured through material evaluation testing methods such as tensile and compression tests. However, since the deformation resistance during cutting processes involves high-speed and large deformations, it is considered difficult to address these conditions with tensile or compression tests under high strain rates, high strain, and high temperature. Our company has established a method for obtaining deformation resistance applicable to cutting processes using the CAE software "DEFORM," which will be introduced in this article. *For detailed information, please refer to the related links. For further inquiries, feel free to contact us.*

• Testing Equipment and Devices

One of the purposes of utilizing sensors in production sites is "defect detection." By using sensors, it becomes possible to visualize the state of forged products and machine movements during the molding process, allowing for the detection of abnormalities such as internal damage and small defects in products that are difficult to confirm using general methods like visual inspection. Furthermore, by implementing appropriate control of the manufacturing line in response to these abnormalities, improvements in productivity and quality management can also be expected. Here, we will introduce a case of detecting ductile fracture defects, which is one of the typical issues in cold forged products. *For more details about the case, please refer to the related link. Feel free to contact us for more information.*

• Other measurement, recording and measuring instruments

We will introduce two application examples of our load sensor "PiezoBolt" regarding the points that those who want to utilize sensors in production sites may have: "How should it be used?" and "How should the measured data be handled?" The first example is the detection of punch breakage occurring during the hole drilling process in sheet forming. The second example is the detection of foreign matter (such as burrs and scrap) contamination. *For detailed information on the examples, please refer to the related links. For more information, feel free to contact us.

• Other measurement, recording and measuring instruments

In the production site of the forging process, are inspection personnel assigned to visually observe and determine the presence or absence of abnormalities in the forging molds, such as cracks or wear? You may have concerns such as: - "It is difficult to set inspection frequency and quantitative judgment criteria." - "There is variability in evaluations." - "There is not enough budget to prepare personnel / training is insufficient." In this article, we will introduce a "system that allows real-time monitoring of mold conditions" by combining bolt-type load sensors with a dedicated system. By utilizing this system, it is possible to detect early signs of abnormalities in the molds. *Details of the case can be viewed through the related links. For more information, please feel free to contact us.

• Other molds

Differential gears (side, pinion) are in high demand for high strength to accommodate the increasing torque due to miniaturization and lightweight design, as well as improvements in engine output. There is a growing request for production using cold closed forging methods. However, forging in a nearly sealed state increases the load on the mold, leading to a shorter mold lifespan, which presents challenges. To address this issue, our company utilized the CAE analysis software "DEFORM" to reproduce "failure," one of the factors contributing to the shortened mold lifespan, and conducted countermeasure studies. Actual case details can be viewed through the related links.

• Other molds

Are you facing issues such as wanting to reduce variability due to work and equipment, wanting to cut material costs, or wanting to improve mold lifespan? With our jointly developed "Automatic Centering Die Set" in collaboration with Beckhoff Automation Co., Ltd. and Dimseed Co., Ltd., you can automatically adjust the position of the mold. In this article, we will explain the overview and application examples of the automatic centering die set. If you are looking to improve process capability and mold lifespan without incurring enormous costs such as replacing press machines, please take a look. *For more details, you can view them through the related links. For further inquiries, please feel free to contact us.

• Press Dies

Our company offers "overseas production" to solve issues such as "I want products delivered overseas" and "I want to receive technical support overseas." We supply molds and forged products from Thailand and China. Utilizing the quality control and manufacturing techniques we have developed in Japan, we deliver products with stable quality. We have fully transferred the technical know-how we have cultivated over many years in Japan to our overseas factories, and we have introduced equipment such as presses, processing machines, and measuring instruments from Japanese manufacturers. We provide high-quality forged products tailored to our customers' needs. 【Features】 ■ Complete transfer of Yamakanako's technical know-how ■ Thorough support for local parts procurement - We can provide consistent support from mold production to parts manufacturing even at overseas factories. It is also possible to manufacture molds in Japan and import them locally. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company identifies existing problems and potential issues, and conducts "process development" to find the most suitable and ideal forms and processing methods. In cutting, grinding, electrical, and finishing processes, we continuously practice the accumulation and transmission of know-how to improve mold accuracy and lifespan. We solve concerns such as wanting to improve productivity, engage in IoT, reduce costs, or develop new forged parts. [Features] - Accumulated know-how in mold manufacturing since our founding - Integration of advanced CAE technology - Achieving low costs and shortening forging processes *For more details, please refer to the related links or feel free to contact us.

• Processing Contract

Are you facing issues such as "poor concentricity due to aging presses," "excessive outer diameter allowances," or "variability in the dimensions of forged products" in your forging production? With our developed die set, the "High Precision Forging System," you can produce forged products with high concentricity unaffected by press conditions. This article will explain the basic overview of the die set, the overview of the High Precision Forging System, and applicable case studies. If you are looking to improve concentricity and increase production efficiency without replacing your press equipment, please take a look. *For more detailed information, please refer to the related links. Feel free to contact us for further inquiries.*

• Press Dies

The term "crack" in molds refers to a state where part or all of the material that makes up the mold is separated. To prevent cracking, it is most important to investigate the cause of the damage. Which factors—people, machines, materials, methods, or the mold itself—are having the greatest impact? It is necessary to investigate whether early damage occurs frequently, under certain cycles or conditions, or if it occurs suddenly. Regarding the improvement of lateral cracks (ring cracks) in molding dies, we have summarized the details on our company page, so please take a look at the related links. *For detailed information, please refer to the related links. For further inquiries, feel free to contact us.*

• Dice

If the mold is damaged, the dimensions of the forged products may change or become scratched, resulting in non-compliance with standards. In the early stages of damage, the changes in the forged products may be small, allowing them to pass through the sampling inspection. If they do pass, it may become necessary to conduct a full inspection, which would force a halt in production during that time. To avoid such a situation, this time we will focus on "vertical cracking of the insert" and introduce methods to prevent damage and extend the lifespan of the mold. *For detailed information, please refer to the related links. For further inquiries, feel free to contact us.*

• Dice

This article introduces the "Non-Stop Production System," which can detect damage that causes variability in tool life, starting from an overview of tool life. As the name suggests, the "Non-Stop Production System" is a system that allows production to continue without interruption. This system is composed of the load sensor "PiezoBolt," which we handle, and the "MMM" from Muratec, enabling real-time control of processing equipment by predicting tool damage and tool life, allowing for tool replacement before damage occurs. [Overview (Excerpt)] ■ If you want to see it in a video, click here! ■ What is tool life? ■ How is tool life determined? ■ Causes of shortened tool life ■ How to extend tool life? ■ The "Non-Stop Production System" that extends tool life *For detailed content of the article, please refer to the related links. For more information, feel free to contact us.

• Production Management System

Are you facing concerns such as wanting to reduce the costs and time associated with 100% inspection or wanting to prevent the outflow of defective products? With our developed 'Smart Forging System,' you can detect whether a product is good or defective 'at the moment of forging' and sort them accordingly. This article introduces the basic overview of 100% inspection, the overview of die sets, and the outline of the Smart Forging System we developed along with its application examples. If you are considering eliminating 100% inspection without replacing your press machines or want to implement measures against defects, please take a look. [Overview] ■ If you want to see it in a video, click here! ■ What is 100% inspection? ■ What is a die set? ■ What is the Smart Forging System? - Composition of the Smart Forging System - Application examples of the Smart Forging System *You can view detailed content of the article through the related links. For more information, please feel free to contact us.

• Sorting machine

We will respond to all requests, from the development of new construction methods to prototypes using mass production presses. With our well-equipped prototyping facilities, we can provide the necessary environment for development using our own equipment, eliminating the need for new capital investment and reducing development costs and production preparation man-hours. 【Development Examples】 - Sheet forming: Drum clutch - Extrusion: Hollow components - Extrusion: Helical gear - Extrusion/Insertion: Spiral bevel - Divergence/Insertion: Pinion gear - Reverse taper forming: Speed gear - And more.

• Other processing machines

Using the piezoelectric load sensor "PiezoBolt," we measure loads and analyze phenomena occurring at "processing points" that were previously unseen. Based on the analysis results, we identify precursors to the occurrence of defective products and implement countermeasures against defects. This solution addresses various challenges in the production site, including equipment maintenance and anomaly detection. 【Monitoring Examples in Forging】 ■ Detection of mold cracks ■ Prediction of punch wear and lifespan ■ Evaluation of lubricating oil 【Monitoring Examples in Press Forming】 ■ Detection of punch breakage ■ Prediction of foreign object embedding ■ Detection of scrap accumulation ■ Equipment maintenance for press machines 【Monitoring Examples in Cutting】 ■ Detection of cutting tool defects 【Monitoring Examples in Casting】 ■ Detection of abnormalities in casting formation *For more details, please refer to the PDF document or feel free to contact us.

• Other electronic measuring instruments

DEFORM is a manufacturing CAE software that utilizes cutting-edge numerical computation technology to simulate various processing phenomena on a computer, such as the flow of metal materials, load conditions on tools, deformation due to heat treatment, and chip prediction during cutting. 【Manufacturing processes that can be analyzed with DEFORM】 ◎ Cold, hot, and warm forging ◎ Cutting (turning, milling, drilling, etc.) ◎ Heat treatment (quenching, carburizing, etc.) ◎ Sheet forming and sheet forging ◎ Roll forming ◎ Extrusion ◎ Plastic fastening ◎ Cogging

• Other analyses
• Other production management systems

At Yamanaka Gokin, we specialize in the production of precision cold forging molds, as well as warm, hot, and cold composite forging molds, non-ferrous metal forging molds, and flow forming molds, tailored to various forming processes. 【Features】 　◎ Cold Forging 　　- High precision and high strength 　◎ Warm, Hot, and Cold Composite Forging 　　- Accommodates complex shapes 　　- Achieves large net shapes 　◎ Non-Ferrous Metal Forging 　　- Realizes lightweight and energy savings 　　- Accommodates complex shapes 　◎ Flow Forming 　　- Accommodates complex shapes such as tooth profiles

• Press Dies

At Yamanaka Gokin, we design, manufacture, and sell various types of closing die sets, including spring-type, hydraulic-type, and hybrid-type. In particular, our unique spring-type closing die set, which uses special springs, contributes to energy savings and space efficiency. 【Features】 　◎ Spring-type die set 　　- Can be installed on presses with low shut heights 　　- Capable of high-speed closing forging 　　- Simple structure makes maintenance easy 　◎ Hydraulic closing die set 　　- Supports high closing force 　　- Contributes to resource conservation

• Forging Machine

PiezoBolt is a load sensor that incorporates a piezoelectric sensor unit embedded within a bolt that meets JIS standards. By utilizing the piezoelectric effect, which generates voltage when force (pressure) is applied, it is capable of measuring minute changes in load. When combined with a measurement system, it enables real-time monitoring of equipment and tools, as well as anomaly detection. ◎ High Sensitivity Excellent responsiveness, allowing for highly sensitive measurements. ◎ Ease of Use Compliant with JIS standard bolt sizes, it can be installed directly in place of existing bolts for measurement. ◎ Durability With a dust and water protection rating equivalent to IP65, it can be used up to 80°C. A high-performance sensor suitable for mass production environments. ◎ Flexibility The piezoelectric element responds to axial forces, detecting changes not only in compression but also in tension.

• others
• Other measurement, recording and measuring instruments