We provide integrated in-house support from mold design to manufacturing,
shortening delivery times and reducing costs.
In-house designed and manufactured mold to meet customer needs
While many companies outsource the production of dies, Arai Parts has been able to improve its heading technology and product development capabilities by designing dies in-house.
Even with special molds requiring complicated shapes and mechanisms, we will meet the needs of our customers with the technical know-how we have cultivated over the years.
After listening to customer's request in details, we will make full use of 3D CAD to study the process and design the mold. Furthermore, we have enabled flexible process design by performing machining analysis in advance using CAE software "3D deformation".
In addition to examining whether the products can be possible at the mass production level, we select the optimum material, select the optimum processing method, and propose the shape, which leads to cost reduction of the product and improvement of production efficiency.
Analysis by 3D deformation
We have accumulated the know-how by using in-house "3D deformation", processing analysis and mold manufacturing.
While improving our unique technology, we are working on shortening the delivery time and reducing costs by manufacturing in-house.
- Analysis within 3D deformation
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- Examining the shape of the mold.
- Simulation of processing rate, deformation, etc.
- Simulation for each material with different hardness.
- Simulation of metal deformation, load of each part, breakage, etc.
Selection of appropriate mold material
One mold is formed by combining several parts (molds).
Depending on the shape of the final product, the metal used for the mold varies. Parts of the mold that hits the product are made out of superalloy, and the parts of the mold that do not hit the product are made of ordinary iron.
Since superalloys are hard and use expensive metals, we are reducing costs by considering the materials used in mold so that there are no wasted cost.
- Mold material selection conditions
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- Consideration of the material of the mold depending on the parts material to be processed (iron, stainless steel, aluminum).
- Consideration of the material from excessive load due to the shape being processed.
- Consideration of the material according to the shape to be processed (workability).
- Consideration of the material depending on the processing equipment.
- Consideration of the material according to the shape and intended use.
We will select the appropriate mold material by utilizing the technical know-how cultivated over the years.
Mold making equipment introduction
We will introduce the equipment for mold making.
We own a wide variety of equipment with different characteristics, and can handle a wide range of materials and shapes.
- Relatively easy processing: lathes, drilling machines, milling machines
- Complex and detailed processing: Machining center, electric discharge machine system
Processing in micro units (one millionth of a unit) for finishing may also be done manually by skilled workers.
| Equipment name | Number of units |
|---|---|
| Machining center | 1 unit |
| Wire electric discharge machine | 4 units |
| Electric discharge machine | 2 units |
| Small hole electric discharge machine | 1 unit |
| Lathe | 5 units |
| Cylindrical grinding machine | 1 unit |
| Surface grinding machine | 4 units |
| Drilling machine | 5 pieces |
| Milling machine | 1 unit |
| Multi-processing machine | 1 unit |
Machining center
Wire electric discharge machine
Electric discharge machine
Surface grinding machine
Multi-processing machine
Manufacturing process design example
We perform flexible process design according to the shape of each part.
If it is a part with a simple shape, we will design the process using equipment with a low investment amount so that it will not cost much.
For parts with difficult shapes, we will first design a process that can manufacture the product with cold heading only. If it is difficult to do only by cold heading, we consider the process with a shape that minimizes secondary processing.
We thoroughly consider how to make high-precision molds with high efficiency.
Multi-station parts former process example "shaft"
Multi-station parts former process example "terminal shape"
Multi-station parts former process example "Pinion"
