iwaki fine technology division suruga seiki co., ltd...
TRANSCRIPT
Support development and production of advancedproducts with high-tech precision components
Iwaki’s fine technology will support product development and mass-production for IT Industry machinery, and Auto-mobile parts with our super-precision technology of punch & die utilizing.
Suruga Seiki Co., Ltd.
IWAKI FINE TECHNOLOGY DIVISION
http://www.suruga-g.co.jp
Iwaki Fine Technology Division
Contents1. Profile of Suruga Seiki Co.,Ltd.
2. Introduction of Iwaki Fine Technology Division.
(1) Profile of Iwaki Fine Tech. Division
(3) Summary of Business
(4) Sintered metal business
(5) Hard metal alloy business
(6) Fine Pressing business
(2) History of Iwaki Fine Tech. Division
Company profile of Suruga Seiki Co., Ltd.
(1)Press manufacturing section
(2)Mold manufacturing section
(3)FA manufacturing section
(4)OST Division
(5)Iwaki Fine Technology Division
1
Press・Mold・FA manufacturing section(business related to precision metal mold)
As Precision metal mold related business has been as the core business from the foundation of Suruga Seiki Co., Ltd., Precision Punch & Die for pressing mold has
the top position of the domestic market leader.
The products that has accumulated production system for many years will make
it possible to offer a wide variety of products
of low volume with high quality, quick delivery
And low cost, and will eventually contribute
to Auto-mobile and Electronics industry.
2
Precision Punch & Die Parts(Pressing Punch & Die)
Punch & Die
Mechanical parts
①Punch
②Pilot punch
③Punch guide bush
④Button Die
⑤Block punch
⑥Block die
⑦Precision Punch &Die
⑧Hard metal punch
⑨Hard metal pilot punch
⑩Hard metal button die
⑪Hard metal block punch
⑫Hard metal block die
⑬Parts related to failure detection
⑭Molding process Punch & Die
⑮Irregular shape Punch & Die
⑯Retainer
⑰Ball lock Punch & Die retainer
a)Striper guide pin bush
b)Small parts
c)Material guide・Lifter related parts
d)Guide post bush for Die set
e)Holder guide post set
f)Coil spring
g)Gas spring
h)Urethane spring
i)Clamping & ・mold hold parts
j)Finishing plate ・Finishing block
k)Inspection jig parts
a)
b)
c)
① ②
③
④
⑤
②
⑭ ⑤
④
3
d)
Precision Punch & Die parts(Mold Punch & Die)
Ejector plate
Cavi-core(Cavity& Core)
Ejector pin
Core pin
Mechanical parts
Straight ejector pinJoggling ejector pinCenter collar ejector pinSquare ejector pinEjector sleeveCenter pin
Straight core pinStage core pinTaper-less core pinProfile・Boss in-low core pinBlock core pin・nesting
Date mark・Recycle markAngular pin・Locking blockSlide core・Loose coreGuide rail ・Center railSpool bush・Locate ringRunner・Gate partsElectrodeGuide partsPositioning partsEjector space related productsMold opening control productsCooling related productsTemp.control related productsScrew & Small partsChemical productsCoil spring 4
Precision Punch & Die(Mold Type)products
Straight Core Pin Slide Core
Runner・Gate PartsSpool BushLocate Ring 6
OST Division
Alignment for light axis will be essential to basic research
of optical scientific technology. As the alignment of light axis the positioning equipment as main-line-up has been developed and presented to R&D equipment & machine.
Further, the production equipment
business for the optical components
such as fiber communication, DVD
and LCD will be evolved and
expanded.
8
Optical Scientific Technology Division(Business of equipment related to light)
VSV-1000Main Body
Motorize Z axis Stage
VSV-1000
XY Stage
Monitor
PC/Sequencer
ControllerD220
CCD
Z axis Stage
Driver
GPIB or RS232C
RS232C
URANUS-IO
CW/CCW NTSC/VBS
VBS
Auto Focus Module –Configuration Example11
OSTproducts
Strategy of OST Division (Technical Side)
【DSC【DSC MarketMarket】】
モータ
StageHolder
光軸調整
Lens AlignmentSystem
【FPD【FPD MarketMarket】】
CompositeSystem
・Compact DigitalCamera
・MobileCamera
・CCD forAutomobile
・Film Waveguide
・LED
・Small LCD
13
Trial
R&D
Trial
Production Production
R&D
Proving Image Processing
Optical Sensor
Piezo
AF
FeedbackControl Technology
StageTechnology
Handling Technology
Domestic Network
14
Iwaki Factory(Iwaki City, Fukushima)(Iwaki Fine Technology Division)
Headquarters&Main Factory(Shizuoka City, Shizuoka)(Press Mold FA manufacturing section/OST Division)
Kansai Factory (Sanda City, Hyogo)(Press Mold FA manufacturing section)
World Network
15
SURUGA KOREA(INCHON)Precision die parts production and salesSURUGA SEIKICO.,LTD.
(THAILAND)Precision die parts production and sales
SAICON PRECISION CO.,LTD.Precision die parts and direct-drivemechanical parts production and sales
1st Factory
SURUGA SEIKICO.,LTD.(GUANGZHOU)Precision die parts production and sales
SURUGA SEIKICO.,LTD.(SHANGHAI)
Optical communication devices and system
Design, development, manufacture, sales
SURUGA POLSKA SP.ZO.OFA parts production and sales
SURUGA USA CORP.Precision die parts production and sales
ADS TECHNOLOGIES CO.,LTD.Optical communication devices and systemDesign, development, manufacture, sales
Division profile
Head office
Iwaki factory
Tokyo office
Kansai office
Employees 186(as of April 1,2007)
Factory Iwaki,Fukushima,Japan
Sales office Tokyo(Kanda)
Business domain
・ Sintered metal manufacturing and sales
・ Hard metal manufacturing and sales
・ Fine pressing metal manufacturing and sales
17
Iwaki Factory (200km from Tokyo)
History of IFT Division
18
・May, 1980 Established Fujitsu Sinter Co.,Ltd. by Fujitsu Limited.
→ Started manufacturing of Sintered metal parts
・Oct, 1986 Merged Fujitsu Alloy Ltd. → Started Hard Metal Alloy
Business for Punch & Die
・Mar, 1987 Built Iwaki Factory in Yoshima Industrial Complex, Iwaki
・Apr, 1987 Started production of heads for magnetic tapes
・Aug, 1988 Started polishing business of ceramic print board for
super-computers
・Dec, 1988 Started mass-production of magnetic circuits for
magnetic discs
・Apr, 1995 Started production and sales of electronics equipment,
Data Logger (FATEC21)
19
・Apr, 1998 Started business of precise pressing parts and magnesium
parts
・Aug, 1998 Started mass-production of HDD suspension parts
・Dec, 1998 Acquired ISO9002 Certification
・Mar, 1999 Acquired ISO14001 Certification
・Sep, 1999 Started mass-production of fuel injection nozzle plates ofautomobile
・May, 2002 Changed company name to “Iwaki Fine Technology Co., Ltd.(Bought all shares from Fujitsu Limited)
・Oct, 2003 Acquired Iwaki Fine Technology Co., Ltd. as Suruga Seiki’s new division, “Iwaki Fine Technology/IFT Division”.
・Dec, 2003 Acquired ISO9001(2000) Certification
・Apr, 2005 Announced business consolidation with Misumi Corporation
History of IFT Division
Group Organization Chart
20
Holding Company(1st Section of TSE)Established 2005
MISUMI Corporation
MISUMI Group Inc.
FA Mechanical Element Div.
Die & Mold Components Div.
Electronics Div.
Tool Div.
China Div.
Asia Div.
Europe Div.
FA Mechanical Motion Div.
North America Div.
Operating Company(Former 1st Section of TSE)Established 1963
Operating Company(Former 2nd Section of TSE)Established 1964
SURUGA SEIKI CO., LTD.
Press m
anufacturing
Section
OST Divisio
n
IFT Divisio
n
FA manufacturing
Section
Mold manufacturing
Section
Hard Metal Alloy BU
Fine Pressing BU
Sintering BU
21
(millions of Yen)
net salesthe lastterm ratio
operatingincome
the lastterm ratio
March, 2007 118,139 12.1% 15,642 20.0%
March, 2006 105,408 - 13,035 -
March, 2007 110,322 13.8% - -
March, 2006 96,902 - - -
March, 2007 16,870 2.3% - -
March, 2006 16,488 - - -
March, 2007 2,049 8.2% - -
March, 2006 1,893 - - -
Suruga SeikiCo.,Ltd.
Iwaki FineTechnologyDivision
Consolidated acconting report March,2007
MISUMICorporation
outline
MISUMI GroupInc.
Sintered Metals
Hard Metal Alloys
Punch & Die Parts
Precision Machining
Fine Pressing
Precision Punch & Die
HDD PartsAutomobile Parts
22
BUSINESS OUTLINE ~ Continuous Production from Powder Metallurgy to Machining ~
Powder Metallurgy
Iwaki Fine Technologies’ Sintering technology has Fine Metal Powder (FMP)parts lineup. Full technology covering from powder metallurgy to precise machining.Fine Metal Powder (FMP) is the sintering parts which can be welding and coating with high density and precision by using 10um diameter power metal(1/10 smaller than standard powder).
Sintering BusinessSintering Business
23Strict final inspection.
Inspection
Sintering by high temp. gas environment.
Sintering
Sizing for high dense parts with precise dimension tolerance.
Sizing
Machining
Using Machining center, NC lathe for machining where punch & die cannot shaping.
Treatment
Debarring and sealing treatment.
Mixing Lubricant subsistence with metal powder.
PowderMix
Shaping by powder compacting
Compacting
SinteringBusiness
・High Strength and High hardnessvalue inside.(Strength is stronger than chromemolybdenum steel. Hardness is harder than Carburize burning.)・High Oblation・High Precision《Semisoft magnetic material》
・Higher magnetic with 1P1S (Onepress, one sintering) than 2P2S.・High density by Droplet phasesintering. ・Suitable for magnetic circuit yoke.
《Fine Metal Powder (FMP) Sintering Material》
・Laser Weldability・Coating・High Insulated・Suitable for Optical related parts.
Compared to Tosei Material + Machining. ・Low cost for detailed shape ・Low cost High precision parts ・High productivity ・High production yield rate ・Available for porous material, Cladded material.
《Cu-Mo-Ni- Iron Oxide Hard Sintering Material》
24
《Features of Sintering Parts》
~Features of Fine Metal Power (FMP) parts~
① High Density Products by using approx.10μm of Fine Powder
( Common Powder : approx.90-100μm )
② High Laser Weldability and Easy Plating
③ Very Smooth Surface by Ra 1.5~2μm of Surface Roughness
=Application Example=
<Network Module Case for FTTH><Cassis for Variable Optical Attenuator>
Part(PM Blank)
Cross Section of Product
ONU (Optical Network Unit)
25
26
Pure iron Fe High precision Magnetic sensor gear
Alloyed iron (1) Fe・Cu・C High strength Parts for automobile
Alloyed iron (2) Fe・Ni・Cu・C High strength Parts for automobile
SUS304L (Fine powder) Fe・Ni・Cr High anticorrosion Parts for magnetic disc
SUS316L (Fine powder) Fe・Ni・Cr・Mo High anticorrosion Chemical resistance
Parts for camera
SUS430L Fe・Cr High anticorrosion With magnetization
Parts for magnetic disc
Permalloy Fe・Ni High anticorrosion High magnetic permeability
VCM yoke
Alloyed iron (3) Fe・P High density Yoke
Alloyed iron (4) Fe・P・Sn・Mo High density Easy plating
VCM yoke
SUS304L<Fine Metal Powder(FPM)>
Fe・Ni・Cr High anticorrosion High laser weldability
Parts for magnetic disc Parts for optical communication
SUS316L<Fine Metal Powder(FPM)>
Fe・Ni・Cr・Mo High anticorrosion Chemical resistance
Parts for camera Parts for optical communication
Kovar<Fine Metal Powder(FPM)>
Fe・Co・Ni High laser weldability High jointability with glass
Parts for optical communication (under Development)
Alloyed iron (5) Fe・Ni・Cu・C High strength High Mechanical property
Parts for automobile
Special alloy-related
Iron-related
Magnetic-related
Stainless-related
〜A Table of Sintering Metal Materials 〜
Hard Alloy Business Unit
27
Panasonic・Mitsumi・
Japan Aviation Electronics
Industry ・Shinko
Electric
Alps Electric ・Shin-Etsu Chemical・Canon
Other 200 companies
connector
Lead frame
Baton switch
Magnet
Hard Metal Alloy
(60%)
Pice steel
(20%)
Dice steel
(20%)
2000case/
Month
sales ratio
70%
General
parts
Die of nozzle
Type of mass-
production
(32type)
Prototype
(24type)
Nissan Group・Honda
Group・Hyundai Group
Sharp・
AUO・
NHK Spring ・ Suncall
Panasonic・Mitsumi・ ・
Matsushita Battery・
Ind. ・ Sony・SII
Injection nozzle LCD
HDD connector
Secondary
battery
Hard alloy for
Die and punch of
the core parts
30type/
month
Sales ratio
3
0%
Segment
die
OthersOur main
customer
The
versatile
The Materials The
production
of scale
The production of scale and the line of products
Compacting Semi-SinteringSintering
HIP
Ultra-Precision machining
Inspection
Ball Milling
Semi-Sintering Processing
Ball-milled powder is compacted in a mold.
The powder is presinteredat about 1000℃ Pre sintered metals machined to
make near-net shape parts Sintering in high temperature in vacuum.
Pores are completely eliminated by Hot Isostatic Press (HIP).
The parts are finished to micron-order precision by using highest precision machines.
Strict final inspection
Metal Mold Parts Precision Metal Mold
Continuous production from Material to Completed
Superprecision processing equipment (150sets) possession
We can develop a suitable hard metal material for the press
material.
Reduced works by machining after semi-sintering We can produce die parts in short-delivery and low cost.
28
The feature of our productWill develop and offer hard metal material matched to the feature of the product
main raw material
<We can provide you a suitable hard alloy metals>
our original minute particle alloy metals are adopted
punch and die of stainless steal. We have gotten high
appraisal about shock resistance and abrasion.
Tungsten Alloy
Cobalt
Tantalum ・Chrome
(additive )
Deflective strength
Hardness
Hard
HardGA33(VF-10)
GA30(VM-40)
GA60(VM-60)
GA50(VM-50)
GA40(VM-40)
GA20(VM-20) GA42(VF-30)
Our material variety list
Soft
Soft
mixed powder
29
Six other kinds,
Developing now
<The using material is virgin powder>
Can supply stable quality material since
only virgin powder is used.
FA20(VF-20)
Hard metal of
ultrafine particle
GA22(VF-10)
The feature of our productsWe could achieve the short-term delivery and low cost by the rough cutting at semi-sintering.
・We can make various shape by
machining after semi-sintering
・ Our delivery time:3~4days
(lead time :1week)
・ We could make short delivery and low price by semi-sintering work
cutting external cylindrical grinding machine milling
Product (after semi-sintering)
To Sintering process
30
The feature of productsWe can meet customer’s various kinds of request with our full production facility.
The accuracy of place:±2μm and under
<surface grinding>
Surface roughness: 0.2S and under
<Wire discharge machining (with linear)>
<center less machining>
roundness:0.2 μm and under
Size accuracy: ± 0.25 μmSurface roughness: 0.2S and under
Surface roughness:0.8S and under
Profile at our headquarter : 0.3S
Size accuracy: ± 2 μm
<profile grinding machine> Our skilled worker will do the final stage.such as lapping and assembling
<discharge machining(with linear)>Surface roughness:0.8Sand under
Size accuracy: ± 5 μm
31
Example:microscopic punch work
The range of production :10μm~90μm⇒possible to produce with the tolerance
of submicron(1μm unit)
32
0.02
φ0.035
φ0.6
φ0.6
φ0.01
0.02
φ0.01
Example:Nozzle punching die
【the spec. of oblique angle press】
・oblique angle : 15°~25°
(max. 45°)
・hole size : φ0.140~φ0.250mm
(min. φ0.100mm)
・tolerance of hole:±0.25μm(assurance by punch size
【 the spec. of oblique angle press】
・the accuracy of assembling : 1μm micro
precision adjusting
・the adjusting of clearance : sub micro adjusting
(punch-die hole) control of break line33
die
punch
~45°
The detail of a punchThe whole body of die
(upper and base)
Base punch
Upper punch
Example:progressive die/three dimensional compacting die 【three dimensional compacting press die】
・the accuracy of three dimensional products : 5μm and under
・sizing accuracy : ±2μm
・surface roughness of the parts :
0.4S
・surface roughness of the compacting : 0.2S and under
・warping/ adjusting angles
【three dimensional compacting press die】
・the accuracy of die assembling :
1μm and under
・confirmation of compacting shape from sampling
・correction of warping
・accuracy compacting height : ±5μm and under
Three dimensinal shapeTolerance within 5μm
Our technology for fitting gap within1μm
34
【progressive compacting press die】
The Die for tape/sheet of liquid crystalFinal Products
製品写真
It is important for each parts of accuracy
It is important for a clearance
Assembling accuracy 1μ
The clearance 3μ (equality for the assembling and adjusting)
Sheet T=30μ
35
Precision jig and tools
Waxing
【jig for conveyance】
【jig for automobile】
【jig for suspention relation】
Accuracy of jig : ±0.001mm
flatness : 0.001mm
Wrap finishing : 0.1S(Rmax)
material : Hard Alloy/steel/his steel
waxing : conjugation between Hard Alloy Metal and steel
treatment : coating(PVD etc)/thermal refining/heat treatment
We can provide a micro precision jig.
36
Continuous production of Die
・a proposal of specification (based on our experience)
・engineering support at a study of a specification
・ a study of a specification with CAD data
・ a proposal of specification (based on work)
・a proposal of specification (based on press)
Customer’s Spec.Die Design
Die AssemblyDie Parts Work
Quality Assurance
・die assembly technology
(based on our experience)
・combining die technology
in sub micron
1) adjusting clearance
2) pitch’s accuracy
3) positive accuracy
・ die assembly technology
for precision holes
・die assembly technologyfor diagonally holes
・ die assembly technologyfor ternary shape
・design from a drawing
・best design from a study of a specification
・design from 2D/3D CAD
2D CAD ‘ 1) I-CAD
2) EXCESS
3D CAD
1) uni-graphics
2) solid works
3) neo-solid
・reduced man-hour by data’s transform of CAD-CAM
1) wire cut
2)discharge machining
3) machining center
4) profile
・surface roughness 0.2S
・dimensional accuracy±1μ
・flatness/parallelism±0.5μ
・perpendicularity±2μ
・ternary shape work technology
・refined punch’s production technology
・complex precision parts work technology
・ISO9001
・quality assurance by a system
・various measuring machine
1) three dimensionalmeasuring machine
2) CNC monitor measuring machine
3) shape measuring machine
4) high density second dimensional measuring machine
37
METAL SHEET FINE PRESSING SYSTEM - High precision mold making technology- Fine pressing technology (Precise positioning, High precision ±3um)- Technology for increasing life of punch through PVD coating- High speed continuous micro burring technology for hoop materials (Burr height is under 3um)
IWAKI FT’s Fine Pressing Technology enabling to support Innovative Manufacturing .IFT’s Press Technology offers precision machining with ±1μm accuracy to 18μm thickness metal sheet. Furthermore, IFT’s Advanced Deburring Technology enables to manufacture high precision parts.
Fine Pressing BusinessFine Pressing Business
Coiling
(Roll type)
Annealing
Electrolytic deburring
High speed carrying
Stainless Steal Tape
High Speed Press
High Speed Carrying
Funnel Shape Pressing
Slanting hole pressing
Swage pressing
Pivot pressing
φ25μm
0.1~0.25t
0.2t
0.2t
0.05t0.03t
Press Coiling
38
40
Material :SUS304 Thickness :30µmAccuracy :less than ±5µm
<more than Cpk 1.33>Appearance :No Scratch / Bruise,
No Shape / Color Change
Continuous Press Machining to 30µm Hooped Metal Sheet.
1.Parts for HDD:Dummy Spacer
• Accuracy of Hole Position:less than ±2 µm• Feeding Accuracy:Each Pitch-less than 10 µm16 pitches/frame-less than 20 µm
• Fine Hole Machining:φ0.14mm• Pivot Machining:Accuracy of Height ±5 µm1pitch:6mm
A
41
2.HDD Parts: Load Bar
Part (A) Fine Bending Part (B)
L-bending
(Height of Rib 0.1mm)
U-bending SUS304L Board thickness 0.04mm
1pitch:6mm
BLength 1mm
A-A’断面Section A-A’
42
Fine Forging Press
1.4 times as thick as material
Application:Parts of HDD Suspension Arm
Gasoline Direct Injection Type
Fuel Injection
Piston
Chamber
Exhaust PontIntake Port
Spark Plug
Nozzle Plate
O-Ring
Cross Section of Fuel Injector
Nozzle Plate
Valve Holder
Fuel
Housing
O-Ring
Noxxle Sleeve
Valve Body
Needle & Core
Spring Adjusting Pite
Filter
Fuel Injection
Piston
Chamber
Intake Port
Exhaust Port
Spark Plug
Multi Point Type(with SURUGA Nozzle Plate)
43
Fine Pressed Fuel Injector Nozzle Plate
Gasoline Engine
44
10hole
20hole
30hole
Material SUS304
Thickness 90μm
Diameter Approx . 150μm
Oblique angle 20 degrees
Nozzle Plate of Oblique Hole for Automobile
Punch Side
Die Side
Section (CU)
Section (CU)
・High Precision Punch and Die
・Mechanical Press with Feeding
・Press Machine with XY Axis Stage
・Image Processing
Pressing for slanting holes
・ Precision Punch and Die
・ Mechanical Press with
Feeding
・Image Processing
Drawing・Blanking Process
・ Tape Polishing Machine
・ Ultra Sonic Deburring
Deburring
・Injection
Characteristic
Evaluation Machine
Evaluation
【 Production Process and Development Facilities】Production Process
Development Facilities
Material(In Coil)
Shipment
45
CNC 3D Shape Measurement
System (Mitsutoyo)
Various kinds of measurement equipment to support “IFT Division’s precise processing”
47
Non-contact 3D Shape CNC Vision
Measurement System (Mitsutoyo)Surface Roughness/Contour
Measurement System (Tokyo-Seimitsu)
Non-contact 3D Shape
Measurement System (Mitaka Koki)Video Measuring Microscope(OGP) Measuring Microscope(Olympus)
48
From Designing to Quality Assurance, IWAKI FT offers High Reliability.
Excellent simulation by utilizing 18 sets of CAD / CAM systems and complete QA set-up in assistance with various measurement equipments such as three dimensional measuring apparatus, Scanning Electronic microscope, etc . – They promise to offer High Reliability!Design Technique CAD・CAM Simulation Quality Assurance