金型産業から航空機産業へ From the mold industry to the aircraft industry 航空機産業参入への経過 Course to the aircraft industry entrants 野田金型有限会社 ＮＯＤＡＫＡＮＡＧＡＴＡ Ｃｏ.,Ｌｔｄ 会社概要：1 Company Profile：1 ・創業昭和５３年１０月の老舗 ・Founded in October 1978 of the long-established 社名：野田金型有限会社 Name : Noda processing Co., Ltd. 住所：大阪府高石市高砂３丁目３８番 Address ： 3-38 Takasago Takaishi Osaka 電話：072-268-1006 T E L ： 072-268-1006 FAX：072-268-1007 FAX URL：http://www.nodakanagata.co.jp/ URL ：http://www.nodakanagata.co.jp/ 業種：金型製作・削り出しエルボ製作販売 Industry：Mold production and Shaving elbow sale ： 072-268-1007 ① 会社概要：2 Company Profile：2 沿革： History: 昭和28年 大阪市福島区大開にて創業 平成元年 事業拡大のため現住所に移転 業績： 1953：Founded in Osaka City, Fukushima-ku, 1988 ：Moved to current address for business expansion Performance: 平成２０年 ISO９００１認証取得 JSWベンダー認定（No.479） 平成２１年 特定研究開発等計画認定 エルボの製造方法で特許取得 （特許第4491538号） 平成２２年 戦略的基盤技術高度化支援事業 （エルボ・ＦＳＷ・ダクト) 平成２４年 第４回ものづくり日本大賞 第３７回発明大賞 平成２４年度近畿地区発明表彰 平成２５年 平成25年度全国発明表彰 2008： ISO9001 certification JSW vendor certification (No.479) 2009：specific research and development plan approved Patented method of manufacturing the elbow (Patent No. 4,491,538) 2010：Strategic infrastructure technology sophistication support project (Elbow · FSW · duct) 2012：4th Manufacturing Japan Grand Prix 37th invention Award 2012 fiscal Kinki Invention Award・Small and Medium Enterprise Agency Secretary Award 2013：fiscal year National Invention Award Japan Chamber of Commerce and Industry President Invention Award ② 会社概要：3 Company Profile：3 プラスチック・鍛造・SPMの金型 Mold plastic forging · SPM ③ 日本の金型産業の歴史 History of mold industry 金型産業の現状 Current state of the mold industry ①最盛期(１９９０年）:１３.１１５社 ①Heyday (1990): 13.115companies ②Development with the development of the automobile industry ③Current situation (2014): 8.048 companies ④Decline in overseas transfer of manufacturers ②自動車産業の発達と共に発展 ③現状(２０１３年)：８.０４８社 ④メーカーの海外移転で衰退 大きな原因 A major cause 1：自動車産業への依存度が高い 1：High dependence on the automotive industry 2：85.5% of the mold shop small companies (10people or less76.4％) 3： Lack of funds 4： Human resources shortage 2：金型屋の８８.５％が小規模企業 (1０名以下は７６.４％） 3：資金不足 4：人材不足 ④ 他産業への展開 Expansion into other industries このままでは将来はない It is not the future in this state ①：１１名の会社で出 来ること？ ②：金型加工技術を生 かせる産業調査 ③：異業種交流参加 ④：航空機産業フォー ラムOWOへ参加 ⑤：航空機産業への参 入取り組み開始 ①：It can be in the 11 members of the company? ②：Industry research that capitalize the mold processing technology ③：Different industries exchange participation ④：Participation to the aircraft industry forum OWO ⑤：Entry efforts start to the aircraft industry ⑤ I deepen the knowledge of the aircraft in the visit, tours, etc. Planning: OWO (On the Wing of OSAKA) ASM２００９ Exhibit Boeing Everett Factory tour JAL Haneda maintenance shop visit Rolls-Royce tour ⑥ 航空機産業参入の問題 Problem of entering the aircraft industry ①：各種認定 （ISO9001,JIS9100、NADCAP) ①: various approvals ②：CAD/CAMの違い （機体製作にCATIAが必要 ジェットエンジンはIGES可能） ②: difference of CAD ・ ＣＡＭ ③：難加工材、チタン、インコネ ル、ハステロイ、CFRPへの 加工対応 ③: Hard-to-work material, Titanium, Inconel, Hastelloy X 、CFRP （ISO９００１,JIS Q 9100,NADCAP) (CATIA in airframe production required Jet engine department can be even IGES） ⑦ 削り出しエルボの開発 ①：切削不可能の常識 ②：元材の99％が切屑になる ③：新しい加工法の開発 ④：新しい工具の開発 ⑤：特許の取得 ⑥：発電業界への売り込み ⑦：航空機産業への売り込み ⑧：展示会への出展 ⑨：更なる改良・改善・提案 Development of shaving Elbow ①：Cutting impossible of common sense ②: 99% of the base material becomes chips ③: development of new processing methods ④: development of new tools ⑤: acquisition of patent ⑥: sell to the power generation industry ⑦: sell to the aircraft industry ⑧: Participation in exhibition ⑨: further refinement and improvement and proposals ⑧ 削り出しエルボの開発：① Development of shaving Elbow：① ①：切削不可能の常識 ①：Cutting impossible of common sense ・エルボを製作するには 鋳物、パイプ曲げ、鉄 板曲げエルボしかない ・アンダーカット部分が多 く発生してエルボの削り 出しは不可能である • To fabricate the elbow casting, bent pipe, steelplate is bent elbow only ・加工方法だけでなく検査 も含めた開発が必要 • Undercut part multi Clause is generated sharpener of the elbow and Is out impossible • Processing method to develop the inspection also including not only necessary ⑨ VECTON (Horiguchi Elbow） Single-Piece Cut Elbow Machining Process Forged Material Outer Processing Inside Diameter Processing Finished Elbow Single-Piece Cut Elbow Machining Process ⑩11 削り出しエルボの開発:② ②：元材の99％が切屑に ・需要は高付加価値を求 める業界に限定 ・従来品の内径のみの加 工で材料ロスを軽減 （新工法：HYBRID ERLBOWを開発） ・薄肉化・高精度・高効率 を達成できる Development of shaving Elbow：② ②: 99% of the base material becomes chips • Demand is restricted to industry to obtain the high-value • Reduce material loss in the processing of conventional products with an inner diameter of only (New construction method: Developed HYBRID ERLBOW) ・We can achieve a thinner, highprecision, high-efficiency ⑪ VECTON（Horiguchi Elbow） Production Process Horiguchi Principle and Structure ① Processing with three axis processing machine by 3D CAD/CAM (Digital processing by numerical control) ② True circle maintained in any cross section ③ Can be designed and machined to have walls of various thickness ※ As a derivative technology for failure mode analysis Can exactly reproduce the same shape of the elbow that caused erosion (This method of examination of thinning elbows is accepted in Fukui University.) Cross section of the Horiguchi Elbow with a true circle inner diameter throughout the elbow without any deformation or strain ⑫ 13 削り出しエルボの開発： Development of ③④⑤ shaving Elbow：③④⑤ ③：新しい加工法の開発 ④：新しい工具の開発 ⑤：特許の取得 ③: development of new processingmethods ④: development of new tooｌｓ ⑤: acquisition of patent ・3軸加工機でのエルボ内面 • 3 establishment of elbow inner 加工方法の確立 surface processing method in the axial machine ・内面加工専用工具の開発 • The development of the inner surface machining special ・Global expansion patented by PCT ・PCT特許取得で世界展開 ・Branding by trademark registration ・商標登録してブランﾄﾞ化 VECTON・HYBRID ELBOW VECTON ・ HYBRID ELBOW ⑬ Awards from the most prestigious invention organization in Japan President Horiguchi receiving award President Horiguchi explains the elbow Commendation from Japanese Chamber of Commerce & Industry presented by Hitachinomiya (Emperor’s brother) as one of 10 most important Japanese technologies ⑭15 削り出しエルボの開発 Development of ⑥⑦ shaving Elbow：⑥⑦ ⑥: sell to the power generation industry ⑦：航空機産業への売り込み ⑦: sell to the aircraft industry ⑥：発電業界への売り込み ・肉厚均等で鍛造品から の削り出し • The machined from forgings in thickness evenly ・極薄肉で強度のある難 削材からの削り出し エルボ • Shaving the elbow from the difficultto-cut materials poles with thin in strength ・高精度・流量効率アップ 軽量化などを評価 （重量軽減28～66％） • Evaluation and high-precision, flow efficiency up lighter (Weight reduction 28～66%) ⑮ 削り出しエルボの開発 ⑨ Development of shaving Elbow⑨ ⑨：更なる改良・改善・提案⑨: further refinement and improvementand proposals ・展示会での情報収集 ・現場の悩み解決 ・溶接箇所の減少 ・歪の減少 ・合体品の製作 ・提案型企業へ変貌 ・Information collected in the exhibition ・Itch of site ・Reduction of welds ・Reduction of distortion ・Production of coalescence goods ・Transfiguration to proposal-based companies ⑯ Actual results and proposals to the power generation and aircraft industry Power generation for large elbow Eliminate the bonding at welding ＋ Coalescence elbow of titanium thickness of 1.2mm Conventional products is a wall thickness 3.6 mm. Weight reduction is 66%. ⑰ 削り出しエルボの開発： ⑧ Development of shaving Elbow：⑧ ⑧：展示会への出展 ⑧: Participation in exhibition ・市場開拓と需要動向・ 製品アピール • Market development and demand trends and products appeal • Demonstration to the design and development ・設計・開発へのデモン ストレーション ・展示場での情報収集 (顧客の問題を直接聞く ことが可能になった) • Information collected in the exhibition hall (It has become possible to listen to customer issues directly) ⑱ Recent exhibitions France・Toulouse Aero Mart2014 JETRO Matching UAE・DOBAI MEBA2014 AUSTRALIA AVALON2015 ⑲ Further research and development and the flow rate efficiency demonstration experiment Had conventional product is welded in this part 90 degrees elbow ⇒ 180 degrees elbow ⇒ Coalescence elbow Pressure gauge Manometer Tip nozzle Reflux condenser Flowmeter Reflux condenser Sample Run-up tube The total length of the experimental apparatus is 30 m Large-scale experimental apparatus for carrying out the fluid pressure measurement of conventional elbow ⑳
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