First Production Dept. (NC machining Section /EDM･Wire-EDM Section)

First Production Dept. (NC machining Section /EDM･Wire-EDM Section)

This Dept. manufacture the component parts for mold assembly ,based on the data designed by Engineering Dept.

Bamper mold is one of our main products and the component parts are machined, drilled, and milling-machined by using suitable machine tools. We are proud of the dept., responsible for the major core of mold production. For the more sophysticated production of molds, our dept. gather the requirements from customers and other information, and improve the quality and accuracy of mold by putting the best of our efforts and adding the latest inventive design. The First Production Dept. is constructed by five sections per component such as A section for large and ultralarge mold, B section for middle size mold, C section for component parts , D section for underbody and structure, and E section for electric discharge processing. Metal cutting machine tools including NC high speed Gr processing machine, NC wire cutting machine, NC electric discharge machine, NC milling machine, are effectively used by professional staffs per process, then mold parts with high accuracy are created to satisfy the requirements and desire of customers.

NC machining Section /EDM･Wire-EDM Section

Our sophisticated engineering was appreciated by one of the world-famous atutomotive company.

Since 2002, Yamaguchi-Seiki has started the business directly with the company to manufacture and deliver bumper molds. At the beginning of the business, we were far behind the existing competitors, then we were encouraged and given much spurs by customers and have been learning through trial and error. At 2008 , Yamaguchi-seiki has gradually satisfied the customer and established a very high reputation now, which are source of our pride as the member of the manufacturing dept.

Just “Operators” are not required. Operate and suggesting how to improve accuracy is our hurdles.

Develop machining devices to get designed accuracy and toolings to improve machined quality.

Equipment List

for Main dies
①	Gun drill machine	4
②	Horizontal boring and Milling machine	2
③	Gate type NC milling machine （5-axis）	11
④	Horizontal NC milling machine	2
⑤	Vertical NC milling machine （for 1600 tonage class molds）	7
⑥	Vertical NC milling machine （for 850 tonage class molds）	2
⑦	NC electric Discharge Machine	6

for Components
⑧	Gate type NC milling machine	2
⑨	Horizontal NC milling machine	1
⑩	Vertical NC milling machine（Middle Size）	5
⑪	Vertical NC milling machine（Small Size）	7
⑫	5-axis Vertical Machining	3
⑬	Vertical milling machine	4
⑭	Carbon electrode machine	6
⑮	Wire electrical discharge	6
⑯	NC electric Discharge Machine	5

Overhead traveling crane

（with double hook）
20t／10t	3	5t／2t	1
15t／10t	2	2.5t／1t	1
10t／5t	2	1t／0.5t	1


10t	1
7.5t	1
2.8t	2
1t	1
0.5t	2

Improve experience with development to reduce bumps at even 0.01mm.

Studying and educating human resources are key to ensure high quality and reliablity on mold.

Main mold (cavity and core) machining process

①Machining cooling line

Multiple gun drilling machine with rotary angle indexing table at 0.001°accuracy produces four times as much machining capability as before, which can machine the slanted hole in high accuracy. By changing to MC mode, this equipment can provide milling, counter boring and tapping too.

To respond to high cycle injection molding, we can design and provide deep cooling lines at more than 150 locations for a mold.

②Rough machining

Rough machining equipment can provide deep-cut and high-feed processing by using 80φcutting tool owing to the rigid structure of equipment.

③NC machining for large mold ranging 3000 tonnage class

Double column type machining center with five-face machining is mainly used for a larger mold production such as bumper and instrument panel.
After rough machining, semi-finishing and finishing are provided by 8 units of Okuma MCR-BⅡ, one unit of MCE-A5C and 2 units of the newest MCR-BⅢ in high speed and high accuracy.
By changing the main axis to universal index head can provide horizontal machining at 90 degree as well as slanted cut too.
We have been focused on providing a full range of devices with particular purpose especially on larger molds for customers to produce supreme quality of molds.

④⑤NC machining for middle size mold ranging 1300 to 1800 tonnage class

Machining mainly for door trim and radiator grille. The machine is customised for high column specifications, which can be changed to molds for instrument panel depend on the deep configuration and structure.

⑥ NC machining for small size mold ranging 350 to 850 tonnage class

Wide range of NC processing are possible ranging from 350 to 850 tonnage as well as middle and larger molds.

⑦Electrical discharge machining（EDM）

Three units for large molds, three for middle size and five for small size are in production to meet all size molds. Particularly, we have been focused on reducing the machining time, then shortening the program schedule, our large machine are equipped with two head devices, developed in house.

Component parts machining process

⑪Vertical NC milling machine（Small Size）

Producing small parts required for mold structure in high speed and high accuracy including slanted core, direct pushing core, slide core, and insert core.
※V56i spindle speed in 30,000/rpm
We have been focused on improving productivity by developing machining table in-house to hold multi works at a time.

⑫5-axis Vertical Machining

5-axis machining tool, added 2-axis to conventional 3-axis machine, can simultaneously machine all angles by 5 axis in a high accuracy.
The machine is mainly for large parts as bumper, which were focused in house to enhance quality and productivity.

⑭Carbon electrode machine

The plant produces electrodes for EDM in house, whose material is mainly graphite by six equipment including 3 of Hi speed machining center.

⑮Wire electrical discharge

At this wire cutting process, plate parts after NC machining are cut around the periphery.
This is the cutting method by flowing current to brass wire, which yields higher heat to cut while melting the part.
A cutting process sometimes faces difficulty depend on the material thickness and hardness, while wire cutting can cut rather easily in a high accuracy.