Technology required by customers
Manufacturing eliminating distortion and deformation
Causes for distortion
Cause for distortion is residual stress.
Stress remaining in materials is called as residual stress.
However, such residual stress is not visible.
Great imagination is required to manage this problem of stress remaining inside the material.
Residual stress has significant impact on the shear heat generated during injection molding.
Shear heat is generated when resin flows and is cooled in the mold.
Injection molding→shear stress→shear heating→mold cooling→residual stress→deformation over time→distortion and deformation
Shear heat generally increases near the gate where the path is narrow, but also increases with changes in thickness and reinforcement ribs of the product.
Generation of shear heat increases specifically in the high temperature region of plastic materials such as super engineering plastics Though some parts are filled by using the generated shear heat, on the other hand, deformation (sink marks) is prominent.
Such deformation due to residual stress also causes cracks during subsequent processes such as painting, adhesion, surface and heat treatment, and overload due to assembly.
Proposal of optimal production conditions by the advanced technical capability of Shoki.
Manufacturing with elimination of distortion and deformation-
- （1） Monozukuri that eliminates distortion deformation is a property of resin, which solves the removal of Hisumi.Sori by mold fabrication technology and removes 100% of generated stress in the mold and design data from T0 as a whole Product precision acceptable product → time dimension.Shape deformation Permanent non-occurrence technology proposal was realized with our technology.
- （2） Gate runner structure generating less shear heat
- （3） Mold enhancing cooling efficiency
System configuration based on heat exchanger concept and not product-shaped mold. - （4） Optimized design of 3D geometry (Integrated production from design to mold manufacturing to product mass production)
Meetings
・CAD data / drawings
・3D modeling / processing data
・Data verification
・Mold machining
・Assembling / alignment
・Mold examination
・Prototype trials
・Measurement and evaluation
・Mass production
・Maintenance - （5） After maintenance (Ultra-precision laser welding)
Introduction to equipment
Introduction to some of the equipment used to support the techniques of Shoki.
Shoki has a wide range of equipment to achieve high precision quality.
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6-axis robot insert molding
- 2 types of 14 collars used as inserts for mold and sheet metal
- Product and runner removal
- Fully automatic inspection, and image inspection
- Display of inspection results
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Molding machine
A wide range of molding machines 100 to 850 t class
We also hold a vertical molding machine
(you can check it in the equipment list)
Equipment possessed for mold manufacturing is installed at two factories and it is set up in 3 factory / 5 axis processing machines, machining center, milling machine, lathe, radial drilling machine, electric discharge machining machine, wire processing machine, argon · laser welding etc.
Business details
Introduction to the business content of each division of Shoki.
Shoki promptly responds to needs of customers with a development system based on collaboration.
Manufacturing Department
- Mold manufacturing
- ・Main products are precision molded components (such as camera components) - Medium molded products (such as automotive interior and functional components)
・Materials used range from soft elastomers to super engineering plastics
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Molding site
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Molding site
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Material site
- Mold manufacturing
- ・3D mold design ・3D modeling ・Machining ・Electric discharge processing ・Wire cutting ・General purpose slicing ・Finish polishing
・ Assembled mold combination ・High precision laser welding - What is a good mold?
Shoki does not just provide technology but believes in providing a consistent backup system for collaboration during product development to production and after-sales, and for Shoki, this is the definition of a “Good mold”. -
- (1)Meeting
- (2)Receiving CAD data and product drawings
- (3)3D modeling, drawing creation, and machining data
- (4)Data validation check
- (5)Metal processing - machining, wire, discharge, polishing and finishing
- (6)Confirmation of mold assembly fitting
- (7)Confirmation trials of mold inspection and molding
- (8)Mold transfer and mass production
- (9)After maintenance (modifications, design changes, and repairs)
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design
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processing
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- Inspection
- We are establishing a quality control system at the site that supports quality, surface roughness, shape / contour measurement for quality assurance purposes, and also carries out quality inspection of products.
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3D measurement
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Product inspection
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Product inspection
New Development G
- New development
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Materials required for monozukuri, molds, equipment, tools and inspection equipment ... We will consistently meet customer needs.
Mold that enables ultra-thick molding with thickness t = 25 mm (Voidless high strength)
Mold that enables ultra thin wall molding with thickness t = 0.26 mm (lightweight and compact)
Both of them are realized as a plastic (super engineering plastic) product as an alternative to metal. We will respond to customers' needs, sincerely troublesome from automotive parts, building materials and stationery, familiar things to specialized fields in a serious manner
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New development
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New development
- Amusement
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Using the newly developed know-how, we are working on assembling and inspecting pachislot cylinder from parts.
If you are a pachislot, have you ever thought of "Why does this reel ureare!" "Eyes turn around"?
In order to eliminate the reel of Yule · Fure, we are able to respond with parts accuracy: strain-less die and molding, jig tool for assembling it, inspection machine.
Also, in the past, we used a sheet metal body, but now we realized weight reduction, productivity improvement, cost reduction through all resinification.
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Amusement
Quality Assurance
- ISO promotion
- Kariya, our production base, and the Takahama Plant, we have established a quality management system and are promoting the certification of the international standard ISO 9001.
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Auditor trainingn
- Health and Safety
- In order to comply with the Occupational Safety and Health Act and to prevent occupational accidents, we have established a safety and health system (committee), voluntarily carry out safety and health activities, and are promoting improvement of the work environment of better employees.
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Safety patrol
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Safety education
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Fire fighting training
