[Case Study Collection] Improvement Cases from Full Cutting Processing to Forging Processing (Header Processing)

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last updated：Oct 31, 2018

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Significant mass production and cost reduction are possible compared to full cutting processing! Numerous examples of improvements to forging processing are introduced!

We would like to introduce a case study of processing improvement proposed by Crown Fastener Co., Ltd. We proposed to improve the entire cutting process, which was facing issues such as "production quantities not increasing" and "surface accuracy inside the holes not being achieved, requiring additional processing," by switching to forging processing (header processing). As a result, significant mass production became possible, and the accuracy stabilized due to production with molds. Additionally, it led to increased strength due to work hardening and substantial cost reductions. 【Case Study】 ■Before - Production quantities were not increasing - Surface accuracy inside the holes was not achieved, requiring additional processing ■After - Significant mass production became possible - Accuracy stabilized due to production with molds - Strength increased due to work hardening - Substantial cost reductions achieved *For more details, please refer to the PDF document or feel free to contact us.

Related Link - https://www.crown-f.co.jp/example

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【Other Examples】 ◎ Improvement from Full Cutting Processing to Forging (Header Processing) and Rolling Processing ■ Before - It was a fully cut product, so it had a slotted hole instead of a cross hole. - As a result, automation in assembly was not possible. - The tolerance for shaft diameter was strict, and since the material used was SUS raw material, costs were high. ■ After - By combining header processing and rolling processing, it was changed to a cross hole, enabling automation in assembly at the user’s site. - The shaft diameter tolerance was met through vanishing processing, and the material was changed to iron + plating. - Significant cost reduction was achieved. ◎ Improvement from Cutting Processing to Forging (Header Processing) ■ Before - Conventional forging made it difficult to process irregular shapes, so cutting processing was used. - This resulted in high costs. ■ After - By innovating the transport method, it became possible to forge. - Cost reduction was achieved. *For more details, please refer to the PDF document or feel free to contact us.