Technology / product information

This case introduces how we switched from cutting to pressing in turbocharger valve components, resulting in an 80% reduction in lead time and 15% reduction in cost.
Overview
This case involves the conversion of a motorcycle turbocharger valve component—requiring high sliding precision—from traditional cutting to press processing. While machining achieved a high surface smoothness in the sliding section for smooth piston movement, it involved long processing times, leading to challenges in lead time and cost. Transitioning to press processing delivered significant improvements.
Features
- Material: SPCC, sheet thickness t1.6 mm
- Proven stable supply of 30,000 units/month (over 10 years of continuous production)
- Controlled ratio of shear surface to fracture surface (conventional 4:6 → achieved 8:2)
- High-precision shear surface ensures reliability as sliding components
- Die clearance narrowed significantly to enhance accuracy
Results
- Lead time shortened: 80% reduction compared to conventional methods
- Cost reduction: approx. 15%
- Maintained sliding performance with high-precision shear surfaces
Stable quality ensured even in mass production through process conversion
Advantages of Process Conversion
- Simplified processing steps compared to cutting
- Long-term production sustainability through by proper die maintenance
- Efficient production system well-suited for mass production
Industry Application Examples
- Motorcycles and automobiles
- Fuel system valve components
- Electronic control components
By converting to press processing, we achieved both shorter lead times and cost reductions simultaneously.
For more details, please download the PDF or feel free to contact us.