iwaki fine technology division suruga seiki co., ltd...

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Support development and production of advanced products with high-tech precision components Iwakis 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

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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

⑭ ⑤

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(Pressing type)products

Punch Profile trimming Punch &Die

RetainerButton Die5

Precision Punch & Die(Mold Type)products

Straight Core Pin Slide Core

Runner・Gate PartsSpool BushLocate Ring 6

FA products

Ball screw

Linear bush Slide guide7

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)

OSTproducts

Goniometer stage

XYZ Stage

9

Motorized Rotary Stage

OSTproducts

Manipulator

Optical Sensor

10

Auto alignment system

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

3-Dimensional Shape Measurement System

12

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

16

Iwaki Fine TechnologyDivision

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

39

HDD Outlook

Magnetic Disc Unit

Suspension

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

46

Application Example of Fine Hole Pressing~Nozzle Plate for Head of Ink jet Printer~

Close up

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

Contact Information 

    

Tokyo Sales Office Sudacho Towa Bldg. 8F, 2-4, Kanda, Sudacho 2-chome,

Chiyoda-ku, Tokyo 101-0041

              TEL 81-3-3255-8652 FAX 81-3-3255-8654

                        

Iwaki factory Yoshima kogyodanchi, 8-1, Iwaki City,

Fukushima 970-1144 Japan

TEL 81-246-36-6000 FAX 81-246-36-8931

49