ヤマナカゴーキン List of News Articles

We solve the concerns of designers and developers, such as 'abandoning forging due to complex shapes' and 'long lead times due to numerous prototypes.' Yamanka Gokin, a leading company in mold design and CAE analysis, has launched a 'Forged Product Development Site' that consolidates case studies directly related to solving engineers' challenges. By combining 60 years of expertise with cutting-edge simulations, we strongly support your product development. <Highlighted Cases on the Site> No Cutting: Forging the serration part of bevel gears to achieve both process reduction and improved accuracy. Breaking Limits with Deep Hole Processing: Achieving deep hole forging with an L/D ratio of 10 times, exceeding processing limits. One-Shot Forming of Complex Shapes: Significantly reducing manufacturing costs by utilizing multi-axis compound presses. With optimal method proposals based on over 1,500 insights, we simultaneously achieve reduced development costs, lightweighting, and increased strength. For more details, please refer to the related link.

The advanced feature of the CAE software "DEFORM," known as "strongly coupled analysis," is a method that allows multiple physical phenomena to interfere in real-time. However, in practice, the key consideration is whether the accuracy gained justifies the increase in computation time. In this article, we conducted a comparative verification of strongly coupled and weakly coupled analyses using the forging of helical gears as a subject. We visualized the differences in analysis results from three perspectives: "load," "contact pressure," and "stress." For more details, please refer to the related links.

In optimizing the heat treatment process, it is impossible to separate the flow of gas from the changes in the quality of the workpiece. The CAE software "DEFORM" allows for seamless coupling of fluid analysis (CFD) and gas quenching analysis within the same software. [Key Points of This Case] - Visualization of Gas Behavior: Precisely understanding the velocity distribution and flow bias within the cooling tank. - Prediction of Quenching Quality: Analyzing the temperature and microstructural changes of each part of the helical gear over time according to the flow. - Identification of Cooling Irregularities: Quantifying the heat transfer rates for specific areas such as the tooth tip, tooth root, and inner diameter. DEFORM's unique strength in simulating "from fluid to quenching" in a continuous manner supports next-generation quality design. For more details, please refer to the related links.

In press die design, the settings for "pilot hole diameter" and "vertical wall height" in burring processes tend to rely on empirical rules and trial-and-error. This is particularly true for high-strength steel sheets (high-tensile), where the risks of cracking and thickness reduction are significant, requiring a considerable amount of time to establish conditions. The plastic processing simulation software "DEFORM" addresses these challenges. 【Identify the "correct answer" with CAE before actual prototyping】 By utilizing DEFORM's "Design of Experiments (DOE)" feature, multiple conditions such as pilot hole diameter and punch shape can be digitally verified all at once for formability. This allows for a quantitative understanding of forming limits and cracking risks, enabling the derivation of optimal processing conditions in a short time. For more details, please refer to the related link.

Are you struggling with the phenomenon where holes, which should ideally be "perfectly round," become distorted in the manufacturing of automotive motor cores and electronic components? Even if we can speculate that mold deflection is the cause, measuring the behavior during processing is difficult. As a result, the current situation often involves repeatedly prototyping based on "intuition and experience," leading to enormous time and cost spent on corrections. In this case study, we used the plastic processing simulation software "DEFORM" to reproduce the phenomenon of hole ovalization. We clarified the mechanisms of distortion that had previously been a black box. - Identifying factors: Quantifying the impact of mold and machine rigidity on precision. - Pre-validation: Simulating the effects of countermeasures before prototyping to reduce rework. For more details, please refer to the related links.

Are you struggling with additional costs and delays due to mold cracking, chipping, or excessive tool wear during press forming? Simply simulating the formability of product shapes does not adequately assess the risks on the mold side. Therefore, an effective approach is to combine this with mold load analysis using the analysis software "DEFORM." - Damage Prevention: Visualization of maximum principal stress to identify risk areas for mold cracking and chipping - Improved Lifespan: Predicting the progression of tool wear to support optimal maintenance cycles and material selection - Quality Stability: Precisely simulating variations in thickness and bending accuracy For more details, please refer to the related link.

Are you facing walls that cannot be solved by the "experience and intuition" of the person in charge in process design involving breakage? - Unable to identify the starting point of cracks, leading to reactive measures - Unable to predict changes in "flanging" due to slight differences in clearance - Repeated prototyping and modifications because "you won't know until you try" Especially in precise shearing and complex plastic processing, predicting the progression of breakage and the final shape is difficult, and the uncertainty in design becomes a significant obstacle. In this article, we will reveal a practical approach to "decipher" breakage phenomena in advance using plastic processing CAE "DEFORM." By utilizing "three breakage analysis methods" that are directly linked to on-site decision-making, we will visualize the progression from the starting point of cracks to the flanging shape. We will provide detailed explanations of the recommended utilization points by Yamanaka Gokin that balance reducing prototyping and improving design accuracy. For more details, please refer to the related link.

Are you facing such walls when trying to examine complex shape forging processes with CAE? - The computation time is enormous, making it difficult to cycle through PDCA. - Spending several days just to set conditions. - Ultimately, the results do not match the actual machine behavior and cannot be fully utilized. Especially for difficult shapes like two-stage helical gears, the "computation cost barrier" from 360° full model analysis becomes a significant obstacle. In this article, we will reveal the efficient analysis process utilizing "sparse gear segmented model (90°) × DEFORM" practiced by Yamanaka Gokin. First, we will use a fast segmented model to get a preliminary assessment, and then conduct full model verification in the final stage. We will provide a detailed explanation of a method that truly helps in practice, achieving a balance between computation cost and accuracy. For more details, please refer to the related links.