[Processing Example] Warped Shape - For Those Who Don't Want to Leave Traces of the Number of Processes
Introducing examples of warped shapes that are prone to failure in the prototyping and design of metal press molding. An explanation using illustrations categorized by shape!
We will introduce the key points for designing metal press parts that do not fail. Parts with warped shapes have a longer circumferential dimension on the underside than on the top side, and the excess difference manifests as wrinkles or overlaps in the bottom part of the top side. Such shapes are unsuitable for mating surfaces with counterpart parts. While increasing the number of processes in the mold can alleviate this issue, it can lead to a significant increase in costs. Our company resolves this by keeping the top side flat, dividing it into two parts, and integrating them through methods such as spot welding. 【Overview】 ■Failure Cases - The underside has a longer circumferential dimension than the top side, resulting in wrinkles or overlaps. - Increasing the number of processes in the mold leads to a significant cost increase. ■Solution - Keep the top side flat, divide it into two parts, and integrate them through methods such as spot welding. *For more details, please refer to the PDF document or feel free to contact us. *Our company accepts production starting from one piece. Please feel free to inquire.
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【Equipment Owned *Partial List】 3D CAD/CAM System: 5 units of CAM-TOOL by C&G Systems Gantry Machining Center: 1 unit by Yamazaki Mazak, X2000xY800xZ585, 10000rpm, plus 1 additional unit 3D Laser Processing Machine: 1 unit by Komatsu NTC, X2500xY1300xZ600, 2.5kw, plus 1 additional unit Hydraulic Press: 1 unit by Kawasaki Hydraulic, high-speed 600ton, L3000xW2000xH1500, plus 4 additional units Robot Welder (CO2): 1 unit by Panasonic, TAWERS 350A, movable range φ1400, plus 4 general-purpose machines 3D Measuring Instruments: 1 unit of 3D scanner by Keyence, and 1 unit of contact-type arm by FARO Welding Strength Testing Machine: 1 unit with a maximum measurement load of 30KN and printer output (Various others) ★ We welcome consultations from the design shape consideration stage! 【Example Solutions】 ■ Solutions for shallow shapes can be addressed through innovative construction methods. *For more details, please refer to the PDF materials or feel free to contact us.
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Applications/Examples of results
■Automotive parts: Automotive body structure panels (steel, aluminum), electronic circuit covers, seat inner panels ■Commercial vehicle parts: Low-volume production, 1 to several hundred units per month ■Food industry: Extra-thick pots, hot sandwich plates ■Revival products: Reproduction of discontinued parts ■Construction machinery and heavy equipment: Exhaust pipes, body covers, cabin panels ■Others: Deep drawing for pressure vessels (Φ170×H250), building material hardware, blades for blowers and fans, etc. *Our company accepts production starting from one unit. Please feel free to contact us for inquiries. *We are open to consultations from the design shape consideration stage!
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Company information
We are a "convenient press prototype workshop" that can immediately turn design intentions into "shapes" through the production of three-dimensional shaped press parts, such as deep drawing. We are confident that we can serve as a strong supporter of development, promising high precision and speedy prototyping. Please take advantage of our high-potential prototype part manufacturing service, which combines our skilled processing technology with the latest equipment. We also assist in the production of mass-production models using prototype data. 【We respond to needs with specialized services】 ■ Forming technology using hydraulic presses ■ Short delivery times supported by technology and equipment ■ Prototype molds incorporating know-how at various stages ■ Support for small-lot mass production from a single prototype to hundreds of pieces per month *For more details, please refer to our company brochure.
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