1. No category

What is Forging ?
鍛造 or “forging” is a process of
preparing iron by beating it until a
certain shape is created. The
Chinese character 鍛 means to
forge an object until it is strong
and resilient. A typical example of
forging is a Japanese sword. Its
craftsmanship reached a level of
profound perfection which led to
a renowned and cultivated
historical Japanese tradition.
UNPRECEDENTED TECHNOLOGY INTEGRATION
http://toa-arai.com/en
http://toa-arai.com/en/
Toa Forging Co.Ltd.
688-1 Kawagoe-cho Ohazatoyota Mie-gun, Mie 510-8122, Japan
Arai Forging Co.Ltd.
8 Amanohara Ohharashinden Myoko-shi, Niigata 944-0332, Japan
Who are we?
Proudly Introducing Our Forging Technology
Toa & Arai Forging offers you best
available solutions for any kinds
of VA/VE.
Machine-less Precision Forging (1)
Toa & Arai Forging Co. Ltd. is the company which supplies basic precision forged automobile
transmission gear parts, industrial gear-box parts by roll forging mills, max. 3500 metric tons
forging press lines with the supporting facilities such as heat treatment equipment, machining
lines, inspection facilities and so on.
Product Examples
In addition, by means of our unprecedented technology integration, we supply innovative
products, such as machine-less curve plate, spiral pinions & gears, hard-to-machine
material-Inconel hollow engine valves and so on, for Actuator Industry manufacturers,
Automobile Industry, Factory Automation Industry, and various industrial manufactures.
Benefits
JIS 2 forging technology is our newly innovation which allows us to forge a gear without
removing the metal teeth. Not only does this break-through technology achieve great cost /
process reduction, but it has led us to pioneering the automobile components market.
• Spiral Bevel Gear
• Pinion Gear
• Greater cost performance: 25% less
expensive than existing products
• Less production processes
A bevel gear by the new process
(Accuracy: JIS3 Equivalent to ISO 7)
A bevel pinion by the new
process (Accuracy: JIS2
Equivalent to ISO 6)
Process Comparison
Current Process [Spiral Bevel Gear]
Material Cutting
Hot Forging / Annealing
Gear Cutting + Lapping
NEW Process [Spiral Bevel Gear]
Material Cutting
Hot Forging / Annealing
Fine Sizing
Current Process [Pinion Gear]
Material Cutting
Hot Forging / Annealing
Tooth contact pattern by a bevel gear and pinion
Gear Cutting + Lapping
NEW Process [Pinion Gear]
Material Cutting
Hot Forging / Annealing
Fine Sizing
For more detail, visit
http://toa-arai.com/en/
Proudly Introducing Our Forging Technology
Proudly Introducing Our Forging Technology
Machine-less Precision Forging (2)
All-in-one Forging without
Assembling Process
Products, such as a Curve Plate, are usually time- and cost-consuming ones. By providing
“Near-net-shape forging materials”, however, we were able to reduce both time and cost.
Complicated-shaped products are manufactured through our exclusive “Extrusion” forging
technology. It eliminates an assembling process while increasing the intensity and accuracy
of the products, thus leading to “high-quality” and “cost-effective” products.
— Mirror Blanking —
Product Example
Product Example
• Curve Plate
• Pin Carrier Flange
Benefit
• Greater cost performance: 30% less expensive than existing products
Process Comparison
Benefit
• Greater cost performance: 22% less expensive than existing products
Process Comparison
Current Process
NEW Process
Current Process
Flange : Hot Forging Normalizing
Turning Making Holes Press Fitting
Pin : Bar Cutting Normalizing
Turning Press Fitting
Material Cutting
Hot Forging / Annealing
Turning
Hole-drilling and
Both side Chamfering
Gear Cutting
NEW Process
Material Cutting
Near-net-shape Hot Forging / Annealing
Mirror Blanking
Two into One
Flange & Pin :
All-in-one Hot Forging
Normalizing
Turning
Proudly Introducing Our Forging Technology
Inconceivable Shape Forging
At Toa & Arai, what we have is the list of inconceivable shape forging technologies, which
lead to cost and weight reduction while increasing durability of a product.
Product Example
Process Comparison
• Hollow Valve
Current Process
Material Cutting
Benefits
• Greater cost reduction: more than 50%
less expensive than existing products
• Higher engine efficiency, less fuel
consumption
• Valve weight reduction
• Lighter valve, more compact valve device
• Better cooling, longer Life
Tip Heating
Upset Forging
Solution Heat
Treatment
Toa Forging Co.Ltd.
Deep Drilling
Material Cutting
688-1 Kawagoe-cho Ohazatoyota Mie-gun, Mie 510-8122, Japan
NEW Process
We Go Beyond Answers You Look For.
We Forge Not Just Iron but a SOLUTION.
Hot Forging
Solution Heat
Treatment
Cold forging
Contact Us @ Toa & Arai.
Product Example
• Integration with All-in one Forging & Machine-less Bevel Pinion
Benefits
• Greater cost reduction: 20-50% less expensive than existing products
• Further improvement of durability: 15% more durable than existing products
• Material weight reduction: 15% more reduction than existing products
Process Comparison
Current Process
NEW Process
Need only one
part. No need
for assembly
Need several parts to be assembled
For more detail, visit
http://toa-arai.com/en/
Arai Forging Co.Ltd.
8 Amanohara Ohharashinden Myoko-shi, Niigata 944-0332, Japan