Technology and Development System Technology and Production System
Process design capability that determines
quality, delivery punctuality, and costs
What is important in product development is not simply judging whether
products can be manufactured. NICHIDAI considers all stages from the design
stage to the manufacturing process and investigates optimum manufacturing
conditions well balanced for quality, costs, and delivery time.
One of NICHIDAI’s strengths is process design capable of proposing how to
manufacture under conditions best suited for various issues such as complex
shapes, weight reduction, and process shortening.
Predict Before Testing. Reduce Unnecessary Costs.
NICHIDAI utilizes CAE analysis (simulation) to verify product performance
beforehand at the design stage.
It prevents problems and rework after mass production by visualizing stress and
deformation. NICHIDAI also achieves reason-based design by verifying experience-
or intuition-based ideas through simulation.
Advantages for customers
- Reducing the number of prototypes (cost reduction)
- Shortening the development period (shorter delivery time)
- Reducing defect risks (quality improvement)
Cycle of development linked with design, analysis, and evaluation
NICHIDAI enhances quality and development efficiency by linking design, analysis, testing, and cause analysis together as a single flow, rather than separating each of them. It has established a mechanism that prevents defects in advance and guides to optimum design, rather than simply handling design.
Design system (personnel and speed)
A total of 25 engineers belong to the engineering department and an optimum
system is set up for each project.
As the engineering department can flexibly handle even multiple projects, it
satisfies both speed and quality.
3D design (CATIA)
NICHIDAI utilizes 3D CAD (CATIA) to handle complex shapes and high-precision products. It secures feasibility from the design stage by conducting design and verification based on 3D data.
CAE analysis (simulation)
NICHIDAI preliminarily verifies stress, deformation, and other factors
through simulation.
It also verifies experience- or intuition-based ideas through simulation.
Testing and evaluation (In-house testing room)
NICHIDAI possesses an in-house testing room to promptly implement design, testing, and improvement. This enables speedy verification without relying on outsourcing.
Material properties/fatigue evaluation (Advanced equipment)
NICHIDAI evaluates material properties and fatigue behaviors in detail by using X-ray residual stress measurement systems and high-temperature tension-compression fatigue testing machines.
Cause analysis and feedback
NICHIDAI analyzes damage mechanisms by fractography and other methods, and
immediately reflects the results in design and manufacturing.
The design and manufacturing departments coordinate with each other to
prevent recurrence of defects.
Research facilities that enable collection of highly reliable data
Research facilities have been organized to be able to conduct various tests and evaluations related to dies and forging, enabling consistent verification from fundamental tests to applied research. NICHIDAI works on sophistication of elemental technologies and creation of new technologies using various measuring instruments, analytical instruments, and testing apparatuses.
High-precision evaluation system using desktop SEM
Desktop scanning electron microscopes (SEMs) have been introduced to
enhance evaluation accuracy for dies and materials.
This equipment can conduct component analysis using X-ray (EDS), as well
as high-magnification observation, enabling detailed analysis in
microscopic areas.
Usage
- Observing the microstructure of dies and parts (cracks, defects, surface roughness, etc.)
- Identifying the causes of wear and damage by fractography
- Checking material composition and foreign matter contamination by component analysis using X-ray (EDS)
- Evaluation and development support for new materials and surface treatment
Advantages for customers
- This equipment enables the user to observe fine portions, making it possible to identify causes of problems immediately.
- This equipment enables component analysis, which is useful for material selection and troubleshooting.
- High-magnification observation enables the user to accurately evaluate the effects of surface treatment and coating.
- This equipment is high-performance equipment that is difficult for general die manufacturers to introduce, which differentiates NICHIDAI from other die manufacturers.
High-temperature tension-compression fatigue testing machine
This machine is testing equipment that can evaluate the properties of die materials and forged materials in detail in high-temperature environments. It completes measurement within the company, supporting prompt verification and highly reliable product development.
Usage
- Evaluating die materials (evaluating properties and surface texture after heat treatment)
- Evaluating forged materials
- Conducting various evaluation tests in high-temperature environments
Advantages for customers
- Evaluation and measurement can be implemented within the company, enabling prompt response.
-
Tests can be conducted in high-temperature environments.
(There are few die manufacturers who own heating furnaces and can conduct high-temperature tests.)
Material and Die Evaluation Using High-Temperature Wear Testing
We have introduced a high-temperature wear testing machine capable of
measurements at temperatures of up to 1,000°C to evaluate the wear
resistance of dies and materials.
By quantitatively evaluating wear behavior under high-temperature
conditions, we can verify performance under conditions that closely
replicate actual operating environments.
Usage
- Evaluation of wear characteristics of die materials and workpiece materials
- Measurement of wear behavior and durability under high-temperature conditions
- Performance comparison of new materials and surface treatments
Advantages for customers
- Testing at temperatures of up to 1,000°C enables evaluation under conditions close to actual operating environments.
- Wear volume and wear rate can be quantitatively measured.
- Product service life can be predicted, and the causes of failures can be identified.
- High-precision testing helps shorten development time and improve product quality.
Testing Equipment
| Testing machine names | Test item | Year of introduction |
|---|---|---|
| Material tester | Tension / Compression test (50 t) | 1994 |
| Micro Vickers hardness meter | Measures the hardness of die and forging | 2015 |
| X-ray residual stress measuring device |
Measurement of Residual Stress and Retained Austenite in Dies and Forged Products |
2017 |
| High temperature tension compression type fatigue tester |
Fatigue test in high and room temperatures (5 t) |
2017 |
| Desktop SEM | Microstructural Observation of Sample Surfaces | 2020 |
| High-temperature wear testing machine | Evaluation of Material Wear Characteristics under High-Temperature Conditions | 2020 |
Advantages for customers
- Using the above equipment enables highly reliable data to be collected during product development or material evaluation.
- NICHIDAI flexibly responds to design planning and proposal according to customer issues or requests.
- We propose the optimal testing methods to meet our customers’ needs and support product development and material evaluation.
