Technical Information｜Toyoda Iron Works Co., Ltd.(TOYOTETSU)

Category lists

1180MPa press

Reducing the weight of the skeleton that makes up the body parts is an essential issue in promoting weight reduction of the car body.
For this purpose, we use a steel plate with a tensile strength of 1180MPa.
They are used mainly for important parts such as the reinforcement of center pillars, rockers passing under doors, and floor cross running right and left under seats, which are related to riding comfort, such as side collisions, offset collisions, and other safety aspects as well as torsion of the car body and abnormal noise during running.

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Bumper Reinforce & Crash Box

Center Body Pillar

Rocker Outer

Rail Outer

Hot Stamping

This is a technology to produce high-strength products of 1470MPa class by heating a material dedicated to hot stamping to about 900℃ and press working, and at the same time holding/quenching it with a die and quenching it into a material.
In addition, because the material is softened by heating the material, it has the advantage that it is easier to produce product accuracy than conventional presses.

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Center Body Pillar

Toyototsu

A micro-convex design structure that enables comfortable touch at low cost.
By changing the layout and angle of the fine convex shape, you can express the feeling of your preference.

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Armrest

Laser Cutting

Since hot stamping material becomes high strength after quenching, drilling and trimming of complicated 3D shapes are carried out by a laser cutting machine.
Laser cutting is performed by exposing the product to light to melt the irradiated part and removing the melted part with high-pressure air.

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Center Body Pillar

Material bonding

Bonding materials are technologies for joining steel plates of different thicknesses and materials. Toyotetsu has five processing methods: mash seam welding, laser welding, plasma welding, laser arc HV welding, and laser filler welding.
It can be machined by the most suitable method depending on the number, shape and material of production.

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FR Extension

Thin Plate Plasma Weld

Plasma welding is a welding method in which oxygen is cut off by plasma gas, an arc is generated between the electrode and the material, and the base material is welded by welding with heat.
Since the welded plate thickness of plasma welding is 0.1mm or more, it is suitable for processing products with thin plates.

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Brake Pedal

Adhesive

Adhesive is used to increase the strength of parts.
Adhesive is applied by the robot, and after application, lengths, heights, and widths are measured by the inspection camera.

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Center Body Pillar

FSW

This is a bonding method suitable for aluminum press parts.
The use of aluminum components due to the need for lighter vehicles is expanding as a substitute for conventional spot welding and arc welding.In the future, it is expected to be used not only for aluminum but also for joining dissimilar materials such as "aluminum × iron" and "aluminum × resin".

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Door Reinforce

The technology provider is here

Embossing

This is a technology for uneven surface finishing in aluminum insulators.
High rigidity can be achieved by machining, and weight reduction and cost reduction can be realized by lowering the plate thickness more than before.

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Heat insulator

The technology provider is here

Product development

We also develop our own products in conjunction with the development that meets the needs of our customers.
Planning and planning → concept examination → structure examination → SE, analysis and component design (design change) were repeatedly carried out, and → prototype production → prototype evaluation was carried out.
Final checks are conducted on products for mass production, and mass production begins.

Development of construction methods

Advances in materials have led to the appearance of high-strength steel sheets, such as ultra-high-tensile steel and hot-stamped steel. The use of high-strength steel sheets is highly effective in reducing vehicle weight and improving crash safety, but on the other hand, forming and welding are difficult.
In order to manufacture high-quality, low-cost products that meet the needs of our customers, TOYOTETSU has developed new forming and welding methods to improve technological levels.

SE

SE (Simultaneous Engineering) refers to the collaboration between customers, who are designers, and in-house production engineering and manufacturing departments, from the early stages of development, to create component shapes that are less costly and easier to make.
By developing proposals for the shape of parts to customers while satisfying the required performance, we are able to shorten the development period, improve quality, and reduce costs.

Product design

Based on the design requirements, such as required performance, presented by the customer, internal requirements are incorporated, and the product shape is examined, created, and drafted. Designed to be a productive/low-cost/high-quality product.

Forming Analysis

Based on product shape data, surface data (virtual real type model required for simulation) is created. The press forming process is simulated and examined in advance so that cracks and wrinkles do not appear in the actual product.
We are analyzing not only cold but also hot stamping materials.

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Crash Simulation

The collision phenomenon is simulated and evaluated on a computer.
This is one of the important tasks for confirming safety performance in developing and designing automotive parts. We conduct a collision analysis of body parts, and consider how the parts are deformed and where high strain and stress are generated, and while considering countermeasures, we aim to propose a lightweight, low-cost structure to our customers.

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Bumper Reinforce & Crash Box

Center Body Pillar

Strength analysis

This technology is indispensable for machine design such as functional parts.
Strength analysis simplifies the prototype phase and shortens the development period.
We have CAE specialized departments and conduct various analyses besides strength analysis.

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Brake Pedal

Parking Brake Pedal

Topological analysis

In topology optimization analysis, the computer derives the optimal solution by defining constraints, strength target values, etc. in the space to be designed.
A novel optimization shape that is not constrained by existing concepts that cannot be imagined by humans also leads to a new idea for designers.

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Brake Pedal

Forming Evaluation

When the product panel is completed, it checks and evaluates where and how it differs from the forming analysis.
As an evaluation method, the product panel was cut with a laser to evaluate the rate of plate thickness reduction.
Check if the numerical value is better or worse than the analysis result.
If it is worse than the numerical value of the analysis result, we will investigate the cause of the deterioration.

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Crash Evaluation

A variety of collision accidents have occurred in the market.
In order to verify how a product can absorb impact force if it collapses during a collision, we destroy the product at high-speed collision, visualize the fracture mode with high-speed cameras and various sensors, and feed it back to design development and crash analysis.

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Bumper Reinforce & Crash Box

Center Body Pillar

Strength evaluation

There are various types of strength evaluation. Tensile, compression, creep, fatigue….
In order to accommodate various evaluations, we guarantee reliable products through product evaluations using various evaluation equipment and experiments.

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Brake Pedal

Clutch Pedal

Parking Brake Pedal

Durability evaluation

Assuming that automobiles will be used for decades, functional products must be guaranteed to be intact even under millions of operations and vibration conditions.
Therefore, we will conduct a durability evaluation continuously for several months.
Our test group also designs equipment and jigs for vibration durability operation.

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Brake Pedal

Clutch Pedal

Parking Brake Pedal

Environmental assessment

Automobiles run over many decades in all areas, ranging from freezing extreme cold to hot temperatures.
Evaluation under various environments is possible.
Low-temperature tanks simulating the Arctic Antarctica, high-temperature tanks simulating deserts, high-humidity tanks like jungles, etc.
Evaluation under various environments is possible.

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Front Door Trim

Sliding Door Trim Board

Press process setting

Consider and set the combination of processes (drawing, triming, bending, etc.) required to manufacture "parts to order" from "steel sheets" and the required press specifications.
Formability is analyzed by molding, and productivity is aimed at setting up a process "no problem in the post-process" by incorporating past defects while communicating with the manufacturing side. In addition, we set the optimum process in consideration of "productivity," "quality," and "cost" according to the conditions of the order received.

Welding process setting

In welding pressed products, industrial robots are used to stabilize quality.
In setting up the welding process, we are considering processes in which both machines and people can work together to produce products, taking into account safety and quality as well as cost.

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Laser Process Setting

Take out and cut the pressed product, and determine the flow until the processed product is packed in a box.
We determine the optimum equipment specifications while considering the work balance between human work and the machining machine.

Assembly process setting

We set up optimal and wasteful processes for human movements and the arrangement of equipment and parts according to the required number.

Die designing

The die face of each process is determined using the forming simulation, and the die is designed based on it.
We decide the die structure in consideration of durability and maintainability according to the specifications of the production press machine, and we are committed to making it worry-free to use in the post-process.
The designer will hear a thump until the mold is completed according to the designed drawing and the first press product is available.

Jig design

The jig necessary for welding or assembling the parts is designed in consideration of workability, etc.
In the designing stage, 3D data are used to check whether spot guns and torches can easily enter the robot, and whether the robot can take a welding posture.

Checking fixture design

When inspecting the product, all dimensions cannot be checked by the measuring tool alone. We obtain from the customer how the target parts are assembled by the customer, where are the standards in that case, and where are the items that must be checked.
Based on this, we manufacture the general-purpose gauge (jig for shape measurement according to the product drawings) and implement quality control in accordance with the customer's requirements.

Die manufacturing

Die manufacturing is a process in which castings and steel materials are actually manufactured after process setting and die design, and can be divided roughly into processes of data preparation, machining, and finish correction.
In the finish correction, the product accuracy is adjusted with a die assembled to fit the die drawing and shipped to the production line.

Jig fabrication

When the jig is manufactured, the jig is assembled accurately while observing 3D data, based on the design drawings.
Then, air piping, work alignment, and electrical wiring are performed to build up.
In the case of mounting on existing facilities, electrical design and field construction are carried out.

Large transfer press

In the 3000t transfer press of a large press machine, automatic production is carried out, and more than 20 products are produced per minute. The size of the bolster (die stand) is more than 6m×2m, and it is used as a press to produce large parts.
In recent years, the number of parts of automobiles that use ultra-high tensile strength materials has increased in order to reduce weight and enhance safety.
In the 3000t press machine, we mainly mass-produce large parts and ultra-high-tensile parts.

Assembly and welding

Components such as pressed products are assembled and welded to finish to the customer's delivery.
We produce a wide range of products in-house, from general welding to complex assembly of brake pedals, etc.

Injection molding

This is a machine for processing resin products. Plastic materials (resin pellets) are melted at high temperatures, poured (injected) into a mold under pressure, and cooled to solidify the resin to form a mold (molding).
The structure of the injection molding machine consists of three devices: a device (controller) for controlling the injection conditions, a device (injection unit) for injecting materials into the mold by melting them, and a device (clamping unit) for holding the mold at high pressure by opening and closing the mold.

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Front Door Trim

Sliding Door Trim Board

Multi Uni Pipe

Armrest

Structure Proposal System

We can be done in-house from development to design, analysis, prototyping, evaluation, and mass production.

Technical Information

Introduce the main technologies of the Toyotetsu Group.

Product Information

Introduce the main products of the Toyotetsu Group.