Product Information

MST Products

Small-lot and low-cost large sintered parts made using an MST technique.

  • A unique technique using a large multistage CNC forming press system that encompasses all steps of the manufacturing process from filling through forming to sintering.
  • The mechanical strength is close to that of the ingot material.
  • Parts can be made with a high accuracy impossible with the conventional mechanical forming presses.

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  • Four Features
  • Cases of Making Parts
  • Cost Benefits
  • Conditions of Making Parts
  • MST Technique

Large sintered parts with high mechanical strength can be provided in small lots and at low cost using the MST technique that encompasses all steps of the manufacturing process from filling through forming to sintering.

Feature 1 High Density  High Density Can Be Achieved by a CNC Press, High Output, and Uniform Filling

The strength of a sintered part is determined by elements such as the density, sintering conditions, alloy elements, and thermal processing. Of these elements, the density is a particularly important element. The high density of MST products can be achieved with one pressing and sintering (1P-1S) operation.

Air holes with a density of 6.6 g/cm³

* The black parts are air holes.

Air holes with a density of 7.1 g/cm³

* The black parts are air holes.

Torsion evaluation with a density of 6.6 g/cm³

Torsion evaluation with a density of 7.1 g/cm³

Feature 2 High Accuracy  High Accuracy Can Be Achieved by a CNC Press, Uniform Filling, and Latest Iron Powder

MST products are made using a CNC forming press system and a unique uniform filling technique with a high accuracy not possible with the conventional mechanical forming presses. In addition, the latest iron powder material ensures stable dimensions.

Accuracy along the height (press) direction in standard sintered parts and the amount of variation from standard values in MST products

Amount of deviation

* The standard size of the measured product is 5 mm.
* The accuracy is as per JIS B 0411 (size classification 6 mm or less).

Feature 3 Complex Shape  Complex Shape Can Be Achieved Using a Multistage CNC forming Press

MST products are formed using a multistage CNC forming press system that controls the pressure, position, and speed with a computer. This enables us to provide parts with a complex shape and large aspect ratio that were previously not possible. In addition, CNC control enables us to make parts with near net shape, without waste and with stable quality. This is an environmentally-friendly technique.


Fill powder

Move powder

Press-form

Take out

Feature 4 High Strength  High Density and High  Strength Can Be Achieved Using Sinter-hardening Material

Thermal processing is effective in achieving high mechanical strength. However, thermal processing after sintering was one of the factors for high costs.
MST products are able to effectively utilize a sinter-hardening material using an accelerated cooling function in the sintering step.

Without accelerated cooling

With accelerated cooling

Spur gear

[Material] Fe-Ni-Mo type materials

[Weight] 0.55 kg

[Density] 7.1g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

For pressure lock gears used in injection molding machines.
Large machined gears can now be produced via sintering.

Outer rotor and the inner rotor

[Material] Fe-Cu type materials

[Weight] 0.3~1.2 kg

[Density] 6.8g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

For large trochoid pumps. Sintering makes possible the manufacture of four types of rotors with varying thickness - traditionally produced via machining - with a single mold.

Rotor and pinion

[Material] Fe-Cu type materials

[Weight] 0.5~1.2 kg

[Density] 6.8g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

For gas station pumps. A high aspect ratio previously unthinkable in powder metallurgy is now possible.

Timing pulley

[Material] Fe-Cu type materials

[Weight] 0.8 kg

[Density] 6.8g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

HV 600+ via induction hardening. Two parts are united in a mold and strengthened via heat treatment.

Plate

[Material] Fe-Ni-Mo type materials

[Weight] 0.8 kg

[Density] 7.0g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

For metal mold counterweights used in bending machines. Production costs of parts previously machined with drawing materials have been successfully reduced via utilization of the sintering method.

Internal gear

[Material] Fe-Ni-Mo type materials

[Weight] 4~5 kg

[Density] 7.0g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

For hydraulics-oriented gear pumps used in presses and injection molding machines. Saves on production costs with a mold that produces yields very close to the final form (near net shape).

Compound gear

[Material] Fe-Cu type materials

[Weight] 0.3 kg

[Density] 6.8g/cm3

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

By using sintering for parts usually made with resin,gear precision and wear resistance are preserved via a single casting and sintering process, enabling shapes not possible via machining processes.

Material molding

[Material] Please consult us

[Weight] Please consult us

[Density] Please consult us

  • High
    Density
  • High
    Accuracy
  • Complex
    Shapes
  • High
    Strength
  • Large
    Size
  • Productivity
    Improvement

Making the most of our large-scale molding machines, we can produce custom samples based on your specified shape and material. We have cylindrical molds available capable of producing casts of up to φ200 mm.

Benefit 1 Lot Size of 500 Pieces or More

Molds must be changed for press forming. A lot size of 500 pieces or more can easily result in a cost benefit considering the time of retooling and other preparations. The standard lot size for quotation is 1,000 pieces.

Relation between lot size and price (%) (rough standard)

500 pieces/lot 110%
1,000 pieces/lot 100%
2,000 pieces/lot 95%

Benefit 2 Total Production Quantity of 10,000 Pieces or More

If the mold costs 2 million yen and a total of 10,000 pieces are made, one piece costs 200 yen. So the total production quantity is a large factor for the total cost.

Benefit 3 The Mass Is 0.5 kg or More

The forming time of MST products is not so much influenced by the size. Therefore the running costs excluding material cost become constant.
Parts with a mass of 0.5 kg or more can easily result in a cost benefit considering the balance with the total cost. The highest cost effective part is one with a mass of 1.4 kg at present.

Benefit 4 Complex Combination of Plane Punch Surfaces

Multiple punches on the punch surface are controlled with CNC making it possible to form a complex shape. A considerable cost benefit can be expected if you are using a milling cutter, etc. at present.

Benefit 5 Materials That Cannot Be Sintered due to Lack of Strength (with a Density of 7.0 g/cm³ or More)

An approximately 1.5 times strength can be achieved for the same material by increasing the density. This enables making sintered parts from materials that could not be used before.

Benefit 6 Materials that Cannot Be Sintered due to Inadequate Output of a Press (with a Diameter of 80 mm or More)

Wide parts can also be made since a large forming press is used.
The larger the size of the part, the larger the cost benefit.

Cases where Cost Benefits Cannot Be Gained

Dimensional accuracy for almost all machining parts is IT7 class or higher
Accuracy in the lateral direction with which MST products can be made at a low cost is 7 or 8 class. If most of the tolerances are 7 class or more, it is difficult to gain a cost benefit since machining is required in the same manner as with other materials.
There are many shapes that cannot be formed with molds
Conventional machining is required since tapping and making undercuts are not possible.
Satisfied with normal sintering
Material cost is the same, but productivity is lower than that of normal sintered parts since a hydraulic molding press is used for MST products. Therefore the cost will increase if no value is added.

Condition 1 Iron Parts

MST products that are made at present are mainly sintered iron parts. The most popular parts are Fe-Cu parts containing 0.6% carbon. Needless to say, they can be processed thermally. MST products can also be made from 300 series stainless steel or other materials.

Condition 2 Parts that Can Be Formed by Vertical Punch

MST products are formed by a vertical punch press. There is a large degree of shape freedom in the height direction, but basically undercuts and holes in the width direction must be added by machining.

Condition 3 Parts with a Maximum Height Dimension of Approximately 80 mm

The maximum height of the part is approximately 40 mm for a 500-ton press and approximately 80 mm for a 1,000-ton press. However, these values are for a simple shape, and if the shape is more complex, the values are smaller. Conversely, if the density is lower, the value may be higher than 80 mm.

Condition 4 Punch area is 1,000 mm² or more

Since presses for MST products are large (500 and 1,000 tons), very small parts are not suitable as MST products. The minimum punch area of the part must be 1,000 mm2(diameter of approximately 40 mm). The size of a part that can be made greatly depends on the shape and the required density. However, we have a track record of having made parts with a diameter of up to 200 mm.

Condition 5 Parts with No Draft Angle on the Side

Since the part is pressed vertically, a draft angle cannot be made on the side. A straight section is required for tapering on the side.

Condition 6 Prototyping materials are available

Molds for prototyping and evaluation cost money. However, prototyping materials taking advantage of the feature of high density are available for the MST products. Prototypes can be made by machining the following prototyping materials for evaluation.

500-ton press: External dia. 80 mm and thickness 10 to 50 mm
1,000-ton press: External dia. 105 mm and thickness 10 to 70 mm

We can also prepared other size of the prototyping materials. Please consult Miki Pulley.

Cases That Require Caution

Impact Load Is Applied
The impact load that the MST products can withstand is larger than that of the conventional sintered parts and high density MST products are also used, for example, in the gears of cars. However, please note that the maximum impact load is lower than that of ingot material due to the existence of air holes.
Process fluid penetrates
Compared to conventional sintered parts, there are less air holes in the surface layer of MST products, since they have high density, but if the MST part is exposed to a liquid, the liquid will penetrate into the inside of the part through the air holes, and then the process fluid may leak up out from the inside and result in deterioration of the surface. This can be prevented by impregnating the air holes with acrylic resin to prevent fluid from penetrating into them.

MST Presses (500-ton and 1,000-ton)

A high-output multistage CNC forming press is used to form high-density, high-accuracy, complex-shaped, and high-strength sintered parts.

Sintering furnace of continuous operation

Parts formed with an MST press are sintered in a mixed atmosphere of nitrogen gas and hydrogen gas. A sinter hardening effect is obtained by controlling the cooling speed after the heating.

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