[Secondary Sheave Piston] Prototype Created by Converting from Casting to Sheet Metal Pressing

► Achieving the Shift from Casting to Sheet Metal Pressing through Process Innovation

※ This article introduces a case study of solving challenges in automotive parts prototyping by converting the manufacturing process of the secondary sheave piston from casting to sheet metal pressing.

[Challenges Faced in the Manufacturing Field]
In the development of automotive parts, there is a growing demand for lighter and higher-performance components. The secondary sheave piston, a crucial part of the CVT (Continuously Variable Transmission), faces weight and cost challenges when using conventional casting methods.

Furthermore, the following challenges emerge during the prototyping phase:
High costs in small-lot, multi-variety production
Difficulty in shortening lead times for both raw material production and machining
Ensuring quality assurance when transitioning manufacturing processes
Environmental and safety concerns in the production facility

Innovative Solution Through Sheet Metal Pressing Prototyping
✔ Advantages of Transitioning from Casting to Sheet Metal Pressing
Significant reduction in processing time through pressing
Control of material thickness during plastic deformation, allowing for extra thickness where needed
Enhanced workplace safety through cold processing
Greater design flexibility, enabling easy shape modifications
✔ High-Precision Processing with Advanced Equipment
Process optimization through press forming analysis
High-quality molds processed with precision machining centers
Stable forming with high-power hydraulic presses
Precision cutting using state-of-the-art 3D laser processing machines
High-precision inspection system using coordinate measuring machines (CMMs)

Key Factors for a Successful Process Conversion
► Comprehensive Support from Material and Process Selection to Quality Assurance
Material and process: Accelerated process optimization through press forming simulation
Cost reduction by minimizing physical trials with digital technology
Workplace improvements through cold processing
Quality: Rigorous quality management system based on ISO9001
► Technical Strengths
Fully integrated system from design to manufacturing
Low-cost and rapid process optimization using digital technology
Extensive processing equipment
Master-level expertise from skilled engineers

Customer Feedback
"We saw significant improvements in QCD (Quality, Cost, Delivery) through process substitution."
— Head of Development, Major Parts Manufacturer A

"The stability of quality was high, and we obtained valuable data for mass production considerations."
— Head of Technical Division, Automotive Parts Manufacturer B

Conclusion
Process conversion through sheet metal press prototyping is an innovative solution that simultaneously shortens development time and reduces costs. In particular, the benefits are evident in the case of the secondary sheave piston.

▶ Download Detailed Technical Materials
More detailed technical documents are available for download at the following URL:
https://ja.nc-net.or.jp/company/22325/dl/catalog/207206

Company Information
Company Name: Timec Co., Ltd.
Address: 197-1 Nishigori, Sōja City, Okayama Prefecture, 719-1164, Japan
TEL: +81-866-93-1269
FAX: +81-866-93-2540
Corporate Website: https://timec.co.jp/
Technical Consultation & Quotation Requests: https://ja.nc-net.or.jp/company/22325/inquiry/