TOOTH PRECISION FORGING - COLD FORGING OF HELICAL GEARS - Cold forging of lightweight, high-rigidity helical gears
The first in the world!
We propose
high-strength, low-cost
helical gears with shafts using
"tooth precision forging" technology.
high-strength, low-cost
helical gears with shafts using
"tooth precision forging" technology.
Manufacturing normal helical gears with shafts requires tooth cutting for each gear, which is time-consuming.
With "tooth precision forging" technology, we can reduce the amount of input materials, capital investment costs, and manufacturing man-hours, so we can provide high-strength helical gears with shafts.
With "tooth precision forging" technology, we can reduce the amount of input materials, capital investment costs, and manufacturing man-hours, so we can provide high-strength helical gears with shafts.
Proposal for using Kaneta’s "tooth precision forging" technology
| Conventional manufacturing method (tooth cut products) |
New forging method (tooth precision forging) |
|
|---|---|---|
| Gear size | Gear specifications (example) module 2.3 | |
| Tooth twisting | Gear specifications (example) 31.5 degrees | |
| Tooth base strength | 100% | High 170%, Medium 130%, Low 250% |
| Cycle time | 60 seconds | 15 seconds |
| Materials used | 100% | 85％ |
| CO2 | - | 100 ton reduction (estimated for 1 million units production) |
- The above table shows a comparison of manufacturing methods using gear specifications used in general automotive parts.
The details will change depending on the part shape presented to us by the customer.
POINT
01We contribute to the improvement of the product appeal of next-generation automobiles
Strength tests confirm that the durability of helical gear products made with conventional gear cutting
is improved by 70% under high load, 25% under medium load, and 150% under low load.
Kaneta’s "tooth precision forging" technology contributes to improving the product appeal of next-generation automobiles by
making drivetrain parts more compact.
is improved by 70% under high load, 25% under medium load, and 150% under low load.
Kaneta’s "tooth precision forging" technology contributes to improving the product appeal of next-generation automobiles by
making drivetrain parts more compact.
S-N diagram, gear cutting product vs. precision forged product
Gear grinding condition of forged gear and cutting gear
Comparison of carburized structures between forged gears and gear cutters. Enlarged view of the tooth base protuberance
POINT
02Increased added value through streamlined production with "tooth precision forging" technology
The world's first "tooth precision forging" technology, which simultaneously applies axial pressing force and rotational force.
One-shot forming eliminates the processing steps, allowing us to create products with an excellent balance of quality, cost, and delivery time.
One-shot forming eliminates the processing steps, allowing us to create products with an excellent balance of quality, cost, and delivery time.
POINT
03Supporting environmentally friendly manufacturing
The "tooth precision forging" manufacturing method, which forms the gear in one shot by cold forging, also contributes greatly to carbon neutrality.
By changing the gear cutting process to forging, we can increase the yield rate and reduce the amount of steel required for manufacturing by 15%.
According to our estimates, if one million gears with a tooth tip of φ53 mm and a tooth thickness of 40 mm were produced, CO2 emissions could be reduced by approximately 100 tons.
By changing the gear cutting process to forging, we can increase the yield rate and reduce the amount of steel required for manufacturing by 15%.
According to our estimates, if one million gears with a tooth tip of φ53 mm and a tooth thickness of 40 mm were produced, CO2 emissions could be reduced by approximately 100 tons.
