ICFG 2021

Development Examples
andPotential of Plate Forging
Takashima City, Shiga Prefecture

HEIAN MFG. CO., LTD.
AKIHIRO MAEDA１．

ＨＥＩＡＮ ＭＦＧ．ＣＯ., LTD.

・Press-forming Company, the history of the manufacturing for establishment of a business 82 years.
・Integrated production system from Development to Sheet metal press-forming, Welding, Painting & Machining.
・Unique press-forming technologies, Plate forging & Precision press-forming, using Large TRF Press.

Establishment
Capital
Number of employees
Location
Main Business
Main Products
Main Customers

July, 1939
60 Million Yen160
Takashima City, Shiga PrefectureManufacture of car parts
T/M, Engine, Body parts etc.
MITSUBISHI, TOYOTA, DAIHATSU,AW-I, EXEDY, etc.

＜Main Facility＞# Press Equipment
・Large TRF Press ：2500t（servo）, 1500t, 800t
・Progressive Press：300t, 400t, 500t
・Small Press：60t~110t etc.
# Die-manufacturing Equipment
Oil Pan
・CAD/CAM System, Wire-Cut Machine etc.
# Welding(Arc-W, PW, EBW etc.), Painting(Cation ED), Machining# Development & Evaluation：CAE, 3D measuring Machine,
Contour measuring Machine etc.

■Main Customers■Main Products

O/D Clutch HubRing Gear integrated
Drive Plate＜Major Prizes＞ “JSTP Medal for Innovative Technology”(1997) /Japan Society for Technology of Plasticity“Japan Manufacturing Grand Prize”(2015) /Ministry of Economy, Trade & Industry“Super Manufacturing Award/Car parts”（2013) /Nikkan Kogyo Shimbun,LTD., MONOZUKURI.NIPPON.conf.

2

Secondary Piston

平安製作所の技術開発年表
１．
年
85

Normal sheet metal forming
Deep Drawing

86

88

90
91
92
93
94
95

Gear Forming

Plate Forging

mass production'87/11～BRKT

Retainer, Bearing

ＯD. HubUD. Hub＊Projection Welding; 10points at the same time,
low cost, low distortion processing

Clamshell Pipe

＊Oil pan by the deep drawing（Compact car, Large truck, Product machine）＊Support Bracket for engine by development technology of welding and production machine＊Plate for engine by large press machine＊Driver's cavine and Fuel tank by weiding and can-making technology（finished in 2001）

Thickend Gear
Forming

Drive Plate ＋ Ring Gear

＊2parts ⇒ Integrated

Exhaust Manifold＊Cast Iron⇒SUS /Sheet Metal

9697

Sheet metal unification

Support, Center

CO2 Weld.

Coining

Cast iron⇒Sheet metal forming

Multipoint PW

Rocker Cover8789

ADC⇒Sheet metal forming

Ring-projection Welding

Oil Pan.

ー History of the manufacturing ーmass production'95/4～

Rocker Cover98

Stractured Catalyst

99

mass production'99/9～

2000
1

mass production'00/4～

mass production'99/5～

Piston for CVT

Near Net Shape2345678

mass production'06/4～

910
11121314
15
16
1718
1920
21

Evolving a forming technology(plateforging,precision sheet metal
forming), welding and machining
technology that we accumulated,
Under development in a new
production method of construction.

Sintering⇒Sheet metal

Lightweight

High Performance

Cost Reduction

New Techniqe

SproketSencing Ring

Laminated Ring Gear

Planet Carrier

Ring Gear(Press)

mass production'20/8～

mass production'10/4～

Injector Support

mass production'10/3～

Compressor CoverGear, Parking Lock3mass production'10/3～

Reversemass production'08/8～

Timing Pulley2．Development Examples of Plate Forging / OD. Hub（Gear forming by Deep drawing)
Punch
Product

Outside diameter φｄ(mm)Die

Influx of material
much lessdrawing
Die dieDie

hproduct

Materials flow

α=15° β=25°

Part A4

Φd(outside diameter)

Development Points① Cast iron + Machining ⇒ Press-forming② Gear forming
・Non lubricant coating・Multi-process forming by deep drawing
・Continuous forming with TRF-Press③ Cost：▲30% Weight： ▲30%

2．Development Examples of Plate Forging / Primary Cylinder
Development Points① 2 ｐarts → Integrated② Avoiding the shear droop of coining region③ Cost：▲25％Weight：▲10%Sensing Plate
Coining method

８ points PW(simultaneously)

Primary Cylinder
Sensing Plate + Primary Cylinder (PW)

Primary Cylinder
integrated with Sensing Platet = 2.0+5.0

t = 5.05Sharp Shapethat controlled dripping2．Development Examples of Plate Forging / Secondary Piston
Development Points① 2 Parts → Integrated② Avoiding the shear droop of a gear forming part③ Cost：▲25％
Weight：▲10%
Sensing Cup

Integrated Sensing Cup

Material filling togear shape<Initial development＞
Cast iron＋Machining

PressFittingDie

Materials flow measures

Sensing part

6

Avoiding shear droopPunch

3．Potential of Plate Forging＜Plate Forging Technology of HEIAN＞
Plate Forming
Shearing

Forging・Integrating multiple parts
・Eliminating processes other than press
・Continuous forming with general press

Plate Forging

Deep Drawing＜Technology Development＞

Bending

・Net shape or Near net shape
・Change plate thickness(increase, decrease）
・Low load

Bulging etc○ Forming load : low△ Forming load : high△ Thickness decrease○ Thickness change: involve(in- or de-crease :possible

・Low load forming・Complex and precise shape forming・High value-added products（high accuracy, low cost)＊Control of the materials flow

[ Own Technology]
・Precision Press-forming
・Partly thickening/thinning・Thickened gear forming
・Precise shearing, etc.
2500tTRF(servo) Press7

3-1) Expansion of Plate Forging Field
Ring Gear + Drive Plate（Welding Assembly）

Ring Gear integrated Drive Plate

Ring Gear(Machining)

Welding
Drive Plate(Press)

Chamfering（Press)

Chamfering(Machining)

Development Point① 2 parts → Integrated (Eliminate welding process)② Partly thickening gear forming③ Continuous forming with TRF Press（Eliminate machining process such as chamfering etc.）④ Cost：▲35％

Weight：▲10%8Pre-formed
Parts

Reduction
Ratio3-1) Expansion of Plate Forging Field＜Characteristics of Thickened Gear Forging＞

With Preform(Preform of gear forming)

Forming Load P (tf)

1. Preform of gear forming by draw forming
2. Accelerate buckling in forging process by preforming
3. Secure gap in forging process by buckling
4. Avoid blockage closed forging by the existence of gap

High Precision Gear Forming with General Press
PreformNo Preform(Cylindrical material)

Materials flow
Upsetting
Punch

Restriction
Punch

Buckling& Thickening

DieForming Stroke S (mm)Gap

Before Forging

Early stage of Forging（Buckling)

Thickening& Gear Forming

End stage of Forging(Gear Forming)

Figure：Effect of preform gear forming
93-2) Potential to expand the application region of Plate Forging
Development of Laminated Gear

Development of Double Cup Pulley（Gear with minimum shear droop）(Timing Pulley)

Reduce noise：▲10～16%

適用例

適用例Weld point＜Conventional Method＞＜Development Method＞
Press（Net Shape）

Sintering + Machining

Laminated Ring Gear

ABA

4.5mm×2 sheets

B

Laminate Welding Technology(22 points simultaneous weld）
Machining

9mm (1sheet）

Shearing Technology
for minimum shear droop

9.0mm

Press Ring Gear

A-A

3.0mm
B-B

（Gear with minimum shear drop）

Normal shearing

Double cup forming technology（Forming from a single plate）
Can be thinned by double sided outercircumference structure (T-shape)

Shear droop

10

4．Conclusion
１．We introduced our development examples of Plate Forging andshowed that it’s a processing technology that allows for complex
and high precision shapes and can reduce costs.
２．For this reason, it was shown that controlling material flow isimportant to overcome problems such as high load for thinning andbuckling for thickening.
３．As shown in the development examples of Ring Gear integrated
Drive Plate, it is shown that by actively utilizing material flow inthe preform gear forming, it is possible to form a thickened Gear
under low loads.
４．We will also work on developing construction method that involves
major changes in material flow and seek to further enlarge
the application domain of Plate Forging.
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