Solution Case (1)
- issue
-
- Helical gears with missing teeth can only be made into molds that require operators to place mold cores
- The cycle time will be very long if operators are required for molding and leads product prices up
Propose a design that enables fully automatic molding in contrast to a semi-automatic molding design
- Solution
- Automatic molding by rotating gear pieces with sliding mechanism
[Effect] Shorter cycle time, lower cost, stable production
Solution Case (2)
- issue
- Due to the thickness of the product, resin causes sink marks and voids
Proposed technology to avoid optimal shape and thickness issuesfrom metal to plastics
- Solution
-
- 1.Optimum wall thickness without sink mark and void. Coring material shape
- 2.Well-balanced gate layout that facilitates fluidity and accuracy in consideration of product applications
- 3.Predict weld line positions where strength will be reduced by using flow analysis and rib placement
[Benefit] Lignten weight, reduce cost, improve productivity
Solution Case (3)
- issue
-
- Sink marks occur at the edge of the tooth and the tooth mating is not uniform
- There is a sound when rotating, and durability is not good
Proposal to correct the tooth lead direction (crowning design) as a countermeasure against noise gear.
- Solution
- Correction of tooth lead direction
Improved tooth contact by crowning design that rounds toward the center of the gear tooth lead
[Benefit] Reduce noise, improve product durability
Solution Case (4)
- issue
-
- Long rack gears
- Deformation due to warpage occurs when 3 pin gates are used as instructed in the drawings
- Additional processes are required to correct warpage, which takes production time
Propose optimal gate position by flow analysis to improve warpage
- Solution
- Flow analysis suggested two pin gate points with minimum warpage
Deformation due to warpage improved by 60%
[Benefit] Improve product precision, shorten delivery time
