澤川鍛造工業 List of Products and Services

We would like to introduce the "Vanishing Process" of Zakagawa Forging Industry Co., Ltd. This process involves moving a tool with a smooth surface against the surface of the workpiece without producing chips, causing plastic deformation and work hardening on the workpiece surface, resulting in a smooth finished surface. The surface roughness and strength are improved, and the surface achieves a mirror-like finish. 【Features】 ■ Processing that achieves a smooth finished surface ■ Improved surface roughness and strength ■ Surface finishes like a mirror ■ Processing accuracy at turning level, surface roughness at polishing level (2s) ■ No need for additional steps such as setup *For more details, please refer to the PDF document or feel free to contact us.

• Processing Technology

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and production of aluminum machined products. Our company possesses processing equipment including "Machining Centers" and "NC Lathes," as well as other machinery such as "Crank Presses" and "Surface Grinders." For inspection equipment, we have machines like "Hardness Testers" and "Three-Dimensional Measuring Machines." 【Main Equipment】 ■Machining Centers ・OKUMA (MA-500HB) ・OKUMA (MX-55VB) ■NC Lathes ・OKUMA (LB 45III) ・OKUMA (LB 4000EX) and others *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

What our customers seek is not just ideas related to technology and manufacturing processes. At times, a perspective from management on how to establish a product as a viable offering is also necessary. At our company, we go beyond mere problem-solving and also consider and propose processing methods that can be offered to consumers from a management standpoint. *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have been actively investing in equipment and improving our productivity through collaboration with young members. While passing on skills from veteran members to younger ones, we have continuously challenged ourselves with new initiatives. We have established a flexible system that can accommodate everything from prototypes to mass production of 1,000 units. *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we procure solid materials and perform turning processing. This allows us to shorten lead times, reduce costs, and achieve quick delivery. Additionally, we collaborate with partner companies for surface treatment, enabling integrated production. *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

Among lathe machining, we are particularly skilled in the fields of "thin-walled," "high precision," and "vanishing machining." We have also achieved precision in lathe machining that could not be realized with machining at customer sites. By combining over 100 years of experience with our unique ideas and concepts, we will continue to take on various machining challenges. *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

Our company has a proven track record of manufacturing drive system components that serve as the heart of construction machinery, heavy equipment, and industrial machinery, including bearing parts, hydraulic pump parts, and gear pump parts. Since these components are the heart of equipment that performs powerful operations, they require wear resistance, machinability, high strength, toughness, and fatigue resistance. While pursuing high-precision machining, we tackle various challenges with the ideas, creativity, and technical skills we have cultivated since our founding. Please feel free to contact us when you need our services. ■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■ ⇒ We excel in thin-walled and vanishing machining for medium to large sizes! (Thin-walled machining for sizes from Φ100 to φ650mm, with t=2.5mm for aluminum forged materials) ⇒ Leave the idea proposals that ensure technology and high precision to us! (For cast iron parts, we offer high-precision machining with Rmax3.2s through turning, along with suggestions for process shortening) ⇒ We provide stable production capacity with 24-hour operation and consistent quality through the latest equipment! ■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■■□■

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components, which serve as the heart of construction machinery, heavy equipment, and industrial machinery. Here, we would like to introduce our processing achievements for "seismic isolation components (angular parts)." 【Processing Achievements】 ■ Material: S55C ■ Size: 20×34×220L ■ Precision: ±Φ0.05mm ■ Lot: 300 pieces ■ Production Period: 2 weeks ■ Processing Method: Machining Center ■ Features: Surface roughness 6.3s *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components, which are the heart of construction machinery, heavy equipment, and industrial machinery. Here, we would like to introduce our processing achievements for "hydraulic components (angular parts)." 【Processing Achievements】 ■ Material: AC4C ■ Size: 150×150×60 ■ Precision: ±0.01mm ■ Lot: 200 pieces ■ Production Period: 1 week ■ Processing Method: NC lathe processing, machining center ■ Features: Surface roughness 4s *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components that serve as the heart of construction machinery, heavy equipment, and industrial machinery. Here, we would like to introduce our processing achievements for "hydraulic components (round parts)." 【Processing Achievements】 ■ Material: FCD700 ■ Size: Φ140×24 ■ Precision: ±Φ0.02mm ■ Lot: 3000 pieces ■ Production Period: 1 month ■ Processing Method: NC lathe processing ■ Features: Surface roughness 6.3s *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components that serve as the heart of construction machinery, heavy equipment, and industrial machinery. Here, we would like to introduce our processing achievements for the "round window." 【Processing Achievements】 ■ Material: AC4C ■ Size: Φ100–300 ■ Precision: ±Φ0.05mm ■ Lot: 500 sets ■ Production Period: 20 days ■ Features: t=3.5mm *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components that serve as the heart of construction machinery, heavy equipment, and industrial machinery. Here, we introduce our processing achievements for "Bearings (outer rings)" with a roundness of 0.1mm. 【Processing Achievements】 ■ Material: SUJ2 ■ Size: Φ120×22L ■ Precision: ±Φ0.08mm ■ Lot: 1000 pieces ■ Production Period: 10 days ■ Features: Roundness 0.1mm *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components that serve as the heart of construction machinery, heavy equipment, and industrial machinery. Here, we would like to introduce our processing achievements for "Bearings (Inner Rings)." 【Processing Achievements】 ■ Material: SUJ2 ■ Size: Φ280×32L ■ Precision: ±Φ0.2mm ■ Lot: 200 pieces ■ Production Period: 4 days ■ Features: Roundness 0.1mm *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration
• others

At Zakagawa Forging Industry Co., Ltd., we have a proven track record of manufacturing drive system components, which are the heart of construction machinery, heavy equipment, and industrial machinery. Here, we would like to introduce our processing achievements for "bearing components." 【Processing Achievements】 ■ Material: S45C ■ Size: Φ400×120L ■ Precision: ±Φ0.1mm ■ Lot: 15 pieces ■ Production Period: 2 days ■ Features: Roundness 0.1mm *For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. We would like to introduce a case where the processing of expensive copper was converted from cutting to cold forging, resulting in a total cost reduction of 47%. 【Key Achievements】 "Manufacturing costs cut by 47%" "Process conversion (from cutting to cold forging)" "Improved production efficiency" 【Consultation Details】 ■Consultant: Major power components manufacturer ■Product Name: Parts for transformer contacts (annual production of 1,000 units) ■Content: Due to high costs associated with cutting processes, we are consulting on whether cost reduction can be achieved by changing the process to forging. Since it carries 180A of electricity, any burrs pose a fire risk. "No burrs" is a requirement. *For more details, please refer to the catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. We have worked together with our customers to solve various challenges, including consultations on prototypes for new product and product development, as well as proposals to enhance current machining technologies and methods. We support the creation of products that contribute to increased production efficiency, cost reduction, shortened lead times during processing, and reduced processes. *For more details, please refer to our catalog or feel free to contact us.*

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and production of aluminum machined products. We are introducing a case where changing the method of product handling has enabled simultaneous grinding processing at two locations, achieving a reduction in delivery time. 【Key Achievements】 "Reduced 5 processes to 3" "Improved production efficiency due to reduced setup time" "Stable quality and reduced defect rate" 【Consultation Details】 ■Consultant: Major construction machinery manufacturer ■Product Name: Shaft parts used in the engine section of a caterpillar (8,000 pieces of 4 types per month) ■Content: Review of the machining process *For more details, please refer to the catalog or feel free to contact us.

• Casting and metal decoration
• others

When performing conventional grinding processes, it is necessary to change the equipment, but with vanishing processing, tools can be mounted on a CNC lathe, eliminating the need for setup and other hassles. The processing accuracy is at the turning level, and the surface roughness is at the grinding level (2s). Here are some examples of vanishing processing achievements. 【Achievement Examples】 ■ For ring shapes, both inner and outer diameter vanishing processing is possible. - Outer diameter: Φ200–750mm - Inner diameter: Φ50–550mm *For more details, please refer to the catalog or feel free to contact us.

• Casting and metal decoration

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing parts, machining of hydraulic pump components, and the production of aluminum machined products. We have developed our own special jigs for thin-walled turning processing, achieving high-precision machining. Here, we introduce a case where we shortened four processes to two. [Consultation Details] ■Consultant: Construction Machinery Manufacturer ■Product Name: Ring Parts for Internal Gears of Travel Motors ■Content: When machining thin-walled parts on a lathe, the shape of the product deforms during processing, resulting in a lack of precision (roundness). Since broaching for gear cutting is performed in a subsequent process, roundness of 10μm and coaxiality of 15μm are required. *For more details, please refer to the catalog or feel free to contact us.

• others
• Crane and others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and production of aluminum machined products. The challenge of thin-walled processing is the "distortion" of products. To achieve high-precision machining, our company has focused on overcoming this challenge. In addressing the issues of thin-walled turning processing, we have conducted analyses of product specifications and material characteristics, in addition to our years of experience and machining technology, repeatedly engaging in trial and error. Through the accumulation of this machining know-how and ongoing verification, we have realized our unique thin-walled turning processing technology. [Consultation Details] ■ Consultant: Aluminum Wheel Manufacturer ■ Product Name: Aluminum Wheel / Aluminum Wheel Cover ■ Material: A6061 (Aluminum Forging Material) ■ Situation: After heat treatment (T6 treatment), turning processing causes a distortion of 0.8mm due to internal stress. ■ Size: Outer diameter Φ600mm, inner diameter Φ500mm, thickness = 42mm ■ Lot: 100 pieces per year *For more details, please refer to the catalog or feel free to contact us.

• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. We have introduced the lightweight compact robot MZ07 from NACHI, establishing a 24-hour operational system through automation. The introduction of robots aimed at automation has made it possible to reduce lead time and labor costs. 【Features】 ■ Automation of the factory to increase productivity ■ Reduction of man-hours and labor costs by 23% For more details, please refer to the catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. We would like to introduce a case where we achieved a 47% cost reduction by transitioning the copper material processing method. **Challenge: "High production costs"** A major power component manufacturer consulted us, stating that due to high costs associated with machining, they were considering switching to forging to reduce costs. Since the component needs to carry 180A of electricity, any burrs could pose a fire hazard, so "burr-free" was a requirement. **Solution** - We transitioned from machining to cold forging, achieving a spherical shape through plastic deformation. - We also accommodated the machining of two holes using pressing. - We achieved a total manufacturing cost reduction of 47%. **Actual Product** - **Consultant:** Major power component manufacturer - **Product Name:** Parts for transformer contacts (annual production of 1,000 units) - **Material:** Tough pitch copper - **Size:** For 180A (left: 60×40×12), for 90A (right: 51×20×6) For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. We would like to introduce our achievements in realizing short delivery times through innovative ideas for process changes. 《Challenge: "Review of Processing Steps"》 We received a request from a major construction machinery manufacturer to review the processing steps for shaft components used in the engine part of a caterpillar. 《Solution》 - Reduced 5 processing steps to 3 * The grinding (done twice) and finishing processes that were performed to achieve coaxiality were shortened by conducting "simultaneous grinding at two locations." - Setup time was reduced, leading to increased production efficiency. - Quality stabilized, and defect rates decreased. 【Actual Product】 ■ Client: Major construction machinery manufacturer ■ Product Name: Shaft components used in the engine part of a caterpillar (4 types, 8,000 units per month) ■ Material: SCM415 (case hardening material) ■ Precision: ±8μm For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. Burnishing processing is a method that moves a tool with a smooth surface against the surface of the workpiece without generating chips, resulting in plastic deformation and work hardening on the workpiece surface, thereby achieving a smooth finish. The machining accuracy is at the level of turning, and the surface roughness is at the level of polishing (2s), which improves surface roughness and strength, resulting in a mirror-like finish. Typically, when performing polishing processing, it is necessary to change the equipment; however, with burnishing processing, the tool can be mounted on a CNC lathe, eliminating the need for setup and other labor. [Examples of Burnishing Processing Achievements] ■Outer diameter: Φ200–750 mm ■Inner diameter: Φ50–550 mm 　*If it is a ring shape, burnishing processing can be performed on both inner and outer diameters. ■Before burnishing processing Ra0.33 ⇒ After burnishing processing Ra0.05 For more details, please refer to the catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing parts, machining of hydraulic pump components, and production of aluminum machined products. We would like to introduce our achievements in developing a special fixture for thin-walled lathe machining that realizes high precision. 《Issue: "Deformation due to Chuck Pressure"》 When machining thin-walled products with a three-jaw chuck, the shape of the product deforms due to chuck pressure. As a result, we were processing through a total of four steps: rough machining and finishing. 《Solution》 We developed a special fixture in-house, achieving high precision and reduced processes. - The special fixture enables high-precision thin-walled turning machining. * Roundness: 10μm; Concentricity: 15μm - Reduced the rough machining process from four steps to two steps. 【Actual Product】 ■ Client: Construction machinery manufacturer ■ Product Name: Inner gear ring component for travel motor ■ Material: SCM440H ■ Size: Outer diameter Φ160mm, thickness = 9.9mm For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company engaged in the manufacturing of cold-forged bearing products, machining of hydraulic pump parts, and the production of aluminum machined products. Our company has focused on eliminating challenges to achieve high-precision machining. 《Challenge: "Distortion"》 After heat treatment (T6 treatment), turning is performed, but due to internal stress, it distorts by 0.8mm. 《Solution》 In addition to our years of experience and machining technology, we have conducted analysis of product specifications and material characteristics, repeatedly engaging in trial and error. Through the accumulation of this machining know-how and ongoing verification, we have realized our unique thin-walled turning processing technology. 【Product Example】 ■Consultant: Aluminum Wheel Manufacturer ■Product Name: Aluminum Wheel / Aluminum Wheel Cover ■Material: A6061 (Aluminum Forging Material) ■Size: Outer Diameter Φ600mm, Inner Diameter Φ500mm, t=42mm ■Lot: 100 pieces annually For more details, please refer to our catalog or feel free to contact us.

• Casting and metal decoration
• others

Zawakawa Forging Industry Co., Ltd. is a company primarily engaged in the manufacturing of cold-forged bearing products. The sizes we handle mainly range from approximately 100 to 600 mm for round and square items that can be held with both hands. We also deal with many drive system components that serve as the heart of construction machinery, heavy machinery, and industrial equipment. Our company has a proven track record of manufacturing drive system components, including bearing parts, hydraulic pump parts, gear pump parts, brake parts, and seismic isolation device parts, which are essential for construction machinery, heavy machinery, and industrial equipment. If you need thin-walled high-precision lathe machining or vanishing processing, please leave it to us. 【Product Line】 ■ Manufacturing of cold-forged bearing products ■ Machining of hydraulic pump parts ■ Manufacturing of aluminum machined products ■ Manufacturing and sales of titanium driver heads for golf (in-house brand products) ■ Manufacturing of magnesium forged products *For more details, please refer to our catalog or feel free to contact us.

• Safety and consumables