03Process of Works & Equipment
Making of Gears
We use general steel and specialized steel. SC (carbon steel) and SCM (chrome molybdenum steel) materials, multiple diameter sizes are kept in stock with other materials usually available on the same or next day.
Suitable material for tempering metal is utilized. In cooperation with carefully selected heat treatment manufacturers in the local area, we can respond quickly to order requests.
Technicians can act quickly in the high technology field by possessing a variety of types of lathes.
Broaching, Wire Electric Discharge and Electric Discharge Machining
Using a tool called a “broach”, high-precision internal machining operations are performed. Broaching tool design and manufacturing is possible due to detailed blueprints.
Wire Electric Discharge:
A process called “wire electric discharge” is used for internal machining. Immediate processing is possible utilizing a broach cutter or pinion cutters without INV.S machinery. Our factory expertise guarantees precise accuracy to within one micron.
Electric Discharge Machining:
Other highly precise methods, blind hole INV.S processing and helical INV.S processing, allow perfect finishing which is not possible with wire electric discharge machining.
Our cutting method uses a variety of tools. Our company, even compared to a speciality machining center manufacturer, is not inferior in technology. We have the capability to shave special 3D and 5-axis shapes.
We construct precision gears that normal gear manufacturers are unable to make. These include: reverse tapered dock MotoGP transmission gears, ring gear cases for hybrids, dog rings for F1 seamless transmissions, main shafts and three-dimensional Hub contour guides.
A process to cut the gear teeth. By utilizing a high column NC gear shaper, cutting gears for crankshafts and four-wheel vehicle helical gears can be cut at every angle.
Gear Hobs ( gear cutting)
A specialized blade is rotated and can cut gear teeth between module 0.3 to 6. Additionally, as it corresponds to dry hob production, accuracy can be checked in stages during prototype production. Involuted splines are also possible.
Shaving with a re-shear tool creates a smooth, high-precision cross section. Accurate processing is maintained while cutting teeth on the shave cutter after carburizing.
In our company, deburring (the process of chamfering the edges of products) is utilized in mass production. We will handle all types of chamfered shapes.
We place orders suitable to our customers' situation (delivery time, material, etc.) with several, reliable heat treatment manufacturers whom we have long time dealings with.
Surface Grinding – Inner diameter Polishing – Outer diameter Grinding
Outer gear surfaces as well as inner diameters are polished. Extremely high-precision grinding is possible in temperature regulated rooms by skilled technicians.
Introducing the best grinding machine such as the German KAPP, Inc. It is the last mainstay for high accuracy. High technology, which is recognized at KAPP, Inc. is the highest level not only in Japan but all over the world.
A check to determine the desired accuracy at the time of design. This ensures the client company specifications are introduced and satisfies the high levels of user demands.
With outstanding staff and the latest equipment, we perform high level inspections. Inspections and measurements are generally performed with 3D measuring devices in 24-hour thermostatically controlled rooms to assure reliable accuracy.
After the final inspection, products are coated with a rust-proofing agent, packaged with protective material and put in specialized boxes to prevent damage to the merchandise. The products are then reliably transported by the designated delivery date.