Accuromm Central Europe
/ A tool engineering company that supports all work related to tools
Accuromm Central Europe
A tool engineering company that supports all work related to tools
Precision Forging Dies & High-Performance Die Sets
Transforming Traditional Press Work into Data-Driven Forging DX (Digital Experience)
Create complex parts with "Net-Shape" accuracy that eliminates the need for extra cutting or finishing, saving you time and material costs.
Our advanced die sets allow you to perform high-level forging on your current presses—no need to invest in expensive, specialized machinery.
Our "Intelligent Die Sets" use real-time sensors to track wear and predict failures, ensuring every part is perfect and preventing unplanned downtime.
We don't just sell tools; we provide total support—from custom die design and flow analysis to setting up your smart manufacturing system.
Nichidai is a niche top company of precision forging dies. With proprietary technology, no1 share of the market for precision forging dies in Japan. Nichidai provides dies for the production of high-precision automotive parts. Processes materials into complicated shapes through one-time press forging.
As a top maker of precision forging dies, NICHIDAI uses advanced technologies it has developed since its foundation to provide precision forging dies as an optimum solution to meet its customers’ requirements and applications. The company enables the conversion of parts production into net-shape manufacturing through the proposal of optimum engineering methods, including cold forging that gives it a significant edge over its competitors in the industry, warm/hot forging, as well as flow control forging and powder molding in which it is not specialized.
Ideal processing method “Net-Shape production”
Cold forging where forming is performed at room temperature with a high pressure causes high loads onto the die and increases the degree of difficulty in processing. However it provides high precision and strength, contributing to the reduction of resource and energy, and significantly improving productivity. As parts manufacturing will possibly be advanced, sophisticated, and diversified in future, NICHIDAI is working toward the conversion of the process of all formed products to net-shape manufacturing. Forming into final geometry without cutting work).
Comparison with cutting work
| Cutting work | Cold forging （Net-Shape） | Advantages | |
|---|---|---|---|
| Productivity | △ | ◎ | Fast processing speed and high productivity |
| Stock utilization | △ | ◎ | High stock utilization |
| Product strength | △ | ◎ | Tight connection of metal fibers and work hardening improve product strength |
| Processing precision | 〇 | 〇 | Realization of Net-Shape manufacturing with high precision |
Classification by forging temperature
| Cold forging | Warm forging | Hot forging | |
|---|---|---|---|
| Characteristics | Performed at room temperature (or conditions close to room temperature) | Performed at temperatures below recrystallization temperature of the material by heating it | Performed at temperatures above recrystallization temperature of the material by heating it |
| Forging temperature (steel) | Normal temperature （Room temperature） | 600℃～850℃ | 1100～1250℃ |
| Forging load | High | Middle | Low |
| Dimensional accuracy | ◎ | 〇 | △ |
| Surface conditions | ◎ | 〇 | △ |
Case studies of formed forged products
NICHIDAI’s net-shape technology contributes to the development of a wide variety of precision forgings.
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Die set is a guide that secures dies to the press and enables accurate vertical motions. For the improvement of the precision of products, it is required that the die set surely hold dies, concentricity and coaxiality (flatness and perpendicularity) of cope and drag be accurate, and the replacement of dies be easy.
NICHIDAI’s Enclosed Die Set
When attached to a generic press, the “enclosed die set” NICHIDAI has developed has a mechanism to enable complex-shaped products to be forged by customer’s mechanical press. Just changing the length of the pantograph enables the mass production of a wide variety of enclosed forgings.
Comparative table of hydraulic and gas type of die set
Hydraulic | Gas type | ||
|---|---|---|---|
| (1) Actuating force | Mineral oil | N2 Gas | |
| (2) Cylinder / Piston | Special | Generic | |
| (3) Number of pieces | １ | more than 1 | |
| (4) Capacity range (set pressure) | 2,000KN | 2,000KN | |
| 〜20MPa | 〜14MPa | ||
| (5) Pressure control | Yes | No | |
| (6) Enclosing stroke | One side | 〜40mm | 〜40mm |
| Both sides | 〜25mm | 〜25mm | |
| (7) Production speed | 〜38spm | 〜580mm/sec | |
| (8) Ancillary equipment | Hydraulic device | − | |
| (9) Other peripheral equipment | Piping, | None | |
Pantograph mechanism
Advantage of enclosed forging
Examples of formed forged products
Reference product list
Hydraulic enclosing mechanism with pantograph system die set
[Specifications (actual production)]
Hydraulic back pressure die set
[Specifications (actual production)]
Gas pressure enclosed die set
[Specifications (actual production)]
Gas pressure enclosed die set
[Specifications (actual production)]
Refer to our catalog for details
Visualize dies damage and product defects, aiming for a production system that does not produce defects.
Traditionally, abnormalities in the dies were determined through visual inspection of the product by skilled workers. However, by visualizing the condition of the dies with sensors, changes such as damage or wear can be detected in real-time based on data, enabling optimal management of the dies.
Visualizing the condition of the dies enables the analysis of collected data to capture phenomena that were previously undetectable, enabling the prediction of its lifespan. Furthermore, we aim to provide our customers with even more valuable services, such as extending the lifespan through maintenance or suggesting replacement timing, based on this information.
Traditional quality evaluation required on-site evaluation of the physical product. However, by clarifying the relationship between data collected during production and product quality, we aim to establish a system that can guarantee quality without directly evaluating the product.
IVI Connected Manufacturing Award 2023 “Academic Frontier Challenge Award”
Our forging DX development won the Academic Frontier Challenge Award at the IVI Manufacturing Awards 2023.
IVI Connected Manufacturing Award 2022 “Grand Prize” winner
Regarding our development of Forging DX (Digital Experience), we have received the Best Award of IVI Connected Manufacturing in 2022. (“Industrial Value Chain Initiative” which is a consortium established to aim for the digital transformation of manufacturing by integrating manufacturing and IT technologies).
Nichidai will achieve Forging DX (Digital Experience) through two technologies:
We will incorporate various sensors for visualizing the condition of the dies into the die set
Visualizing
the inside of
a press as data
Sensors mainly incorporated into the die set
Measure the actual load for each dies during diesing
Measure the distance between diess during diesing
Measure the temperature changes of the dies during diesing
Detect changes in the dies and peripheral equipment through vibration using an acoustic emission sensor
Detect smaller changes in the dies and peripheral equipment through vibration using a vibration (acceleration) sensor
Record the status in conjunction with forging
Customization of various sensors is available according to the customer’s needs. By installing the Intelligent die set, it is possible to collect production data with existing equipment (press machines).
We aim to achieve quantitative quality management by collecting, visualizing, and analyzing data during mass production
By combining multiple sensors such as AE, load, and displacement sensors, we can detect abnormalities in diess at a much earlier stage than conventional methods, aiming to prevent product defects and other issues.
Aiming to achieve a production system that does not produce defective products
We may not notice abnormalities in molds even if we monitor them on-site. However, continuing to press with a mold that has abnormalities will result in producing a large quantity of defective products. To solve this challenge through Forging DX, this product has been developed. A major feature is that it can be used with the conventional press machine by only replacing the die set. Nichidai is committed to tackling the long-standing challenge in the mold industry of not producing defective products with all our efforts.