We even manufacture the "dies" that are essential for press processing in-house.
Here, we will explain the process from "mold design to production" that is unique to Yamada Manufacturing.
mold design
Design 1
Design 2
To make the mouldThe most important process.
- We conduct design reviews to design molds based on product drawings and product specifications.If it is a completely new product or material, we will carry out trial and error by using our in-house test molds to carry out test processing.
- Next, we decide on the specifications, including the mold structure, and complete the mold specifications.
- Based on the mold specifications, we design the mold, including the mold layout, and create mold drawings.
- The created mold drawings are checked for errors and design defects.
- From the completed mold drawings, we create production drawings for the parts and plates we will manufacture in-house, and then move on to the next process.
Milling and Machining
NC milling
ROBODRILL
We mainly use milling machines and machining centers to select the cutting tool that best suits the application, and then perform cutting processes such as drilling, tapping, grooving, and chamfering on the steel material.
Basically, the parts that directly affect product quality are not completed through "milling and machining," but are instead completed through the next step, "wire EDM."
Wire electric discharge machining
Wire cutter (made by Seibu Electric)
Wire cut (made by FANUC)
"Electric discharge machining" is performed using a wire-cut electric discharge machine.
Wire-cut EDM machines, which use wire as an electrode, are extremely precise and, unlike milling machines and machining centers, can automatically machine even complex shapes according to a program, making them essential for creating high-precision molds and ensuring product quality.
Grinding
setup
Grinding
Using a surface grinding machine that rotates a grinding wheel at high speed, we perform fine machining to smooth out the unevenness of die plates and punches and make them uniform in height. This is also called surface polishing.
When pressing using a mold, uniformity of height is extremely important.
Since uneven mold height affects quality, we strive to ensure that mold flatness is on the micron level.
We also perform flat surface polishing for mold maintenance.
As the number of press processes increases, the die itself deteriorates (wears away), and the cutting edge of the die needs to be restored.
Assembly
Mold assembly
Mold completed
Die assembly is the process of combining the manufactured die plates and punches one by one.
This is the most difficult process and should only be carried out by qualified personnel.
Yamada Manufacturing's molds are ultra-precise molds, unlike general molds.
Especially when performing the "blade alignment" to align the die plate and punch of the mold,
It requires high skills backed by a long learning period.
Especially when performing the "blade alignment" to align the die plate and punch of the mold,
It requires high skills backed by a long learning period.
