Major Components

Forging/Sintering

History

Year
Hot forging
Cold/Warm forging
Sintering
Die manufacturing
1937
 
 
 
Hand carving until 1954
1954
950-ton billet shear
 
 
 
1957
2,000-ton forging press
 
 
 
1959
 
 
 
Manual copy milling machine
1960
250-kilowatt high frequency induction heater
600-ton cold forging press
 
Hydraulic copy miller
Electric discharge milling
1964
Automatic forging press (for connecting rods [con rods])
300-ton cold extrusion press (for rear shafts)
 
 
1966
Full enclosed die forging
 
 
Precision machining by jig grinder
1967
 
3/4-inch cold former
Small parts sintering (for ball joint balls)
 
1969
 
 
Large sintering (for sprockets)
 
1970
Automatic upsetter (for rear shafts)
Gear shape forging (for spline pieces)
 
 
1972
AMP70 hot former
Large cold former (for drive pinions)
 
 
1974
 
1,200-ton cold forging press (for rear suspension arm ends)
 
 
1976
Automatic forging line (for knuckles)
 
 
Wire-cut die machining
1977
Cross roll line (for counter gears)
 
 
 
1978
Large forging line (for crankshafts)
Roller groove cold forming (for constant velocity joint [CVJ] tulips)
 
 
1980
 
 
 
Die and electrode machining by 3D NC machine
1981
 
 
Powder forging (for con rod)
 
Sintered bonding (for camshafts)
1982
 
Cold and warm complex forming (for CVJ outer races)
 
 
1985
Large hot former line
 
 
 
1987
 
Full enclosed die cold forging (for differential gear teeth)
700Mpa high-strength sintering (for synchronizer hubs)
NC machining of Graphite electrodes
Cold forging (internal spline of differential lock sleeves)
Simultaneous sinter and brazing technology (for planetary carriers)
Cold forging of engine bolts (at Kamigo Plant)
1988
 
 
Stainless sintered parts (for sensor rings)
NC machining of resin die copy model
1989
In-house forging of crankshafts (for S-series engine)
 
 
Thermostatic room for precision machining enhanced
2D simulation "FESTE" developed
Square forging die FMS line
1990
JZ-series con rod fatigue strength improved
 
 
 
Switch to white lubricant from black lubricant
1991
4,000-ton auto forging press for con rods (at Honsha Plant)
600-ton cold former for steering parts
Powder forged con rod
Straight-flow machining line
High-speed hub bolt maker (at Miyoshi Plant)
1992
3,500-ton auto press (at Kinuura Plant)
Switch from phosphate-type lubricant to single-liquid lubricant
 
 
Additional 2,500-ton press (at Toyota do Brasil [TDB])
1993
 
Automatic transmission (AT) carrier (marking a process change from press forming)
 
 
1994
 
Cold roll forming (for near net-shaping of AT sleeves)
Computer NC powder forming press (for near net-shaping of manual transmission [MT] synchronizer hubs)
 
Shot peening
Premix powder
1995
Modified 4A-G con rod fatigue strength improved
1,200-ton hydraulic press for gear shape forging (for transfer parts at Kinuura Plant)
Mass production of resin impregnated pulley
 
3D simulations "DEFORM" and "SUPERFORGE"
1996
CASE activities by 3D solid "Pro/E" (for crankshaft)
Net shaping (for high-strength yield-point fastening bolt)
Aeration powder filling (for high-precision formed hubs)
 
1997
Net shaping (for crankshaft counterweights)
Hydraulic link motion press (at Miyoshi Plant)
 
 
Steering main shaft hollowing (swaging)
Cold bolt former for long engine bolts (at Kamigo Plant)
1998
1CD-series con rod fatigue strength improved
Net shaping (for PS pinion valve groove)
 
 
Con rod process design reformed (at Honsha Plant)
1999
Forging of CVJ parts at Tianjin Toyota Forging (TTFC )
Net shaping (for PS pinion helical gears)
 
 
2000
"Forging die life estimation system" development commenced
1,000-tom hydraulic link press (for CVT parts at Kinuura Plant)
 
 
Net shaping (for CVJ inner roller groove)
2001
 
 
Partial-diffusion alloy premix powder
Thermostatic room renovated and expanded
Precision equipment (surface grinder, wire-cut EDM, form measurer) operated
2002

 
 
Direct-cut machining of bevel gear forging die
2003
Forging of MT parts at Toyota Motor Manufacturing Poland (TMMP)
 
TMMP operation
 
In-house aluminum forging (for the Zero Crown)
Fixed-volume powder supply technology
2004
Compact 5,000-ton press at TMMP (for crankshafts)
 
Operation of new line at Miyoshi Plant
Precision tool grinder
3D simulation "FORGE" for large forging parts
2005

 
 
Direct-cut machining for single-piece first-gear die
2006
5,000-ton press (for crankshafts) at Honsha Plant
Die wear forecast technology for differential gear (in "forging die life estimation system")
 
No-contact 3D laser measuring machine
Die strike condition measurement and traceability system introduced
2007
2,000-ton press at Honsha Plant (for con rods)
 
 
 
2008
Forging of transmission parts at Toyota Motor Hokkaido (TMH)
 
High-strength small gear for Valvematic (VLC) (at Miyoshi Plant)
High-precision and high-accuracy machines (for knuckle dies)
2009
2,500-ton press introduced, allowing start of forging of large gear with parking gear (at Kinuura Plant)
 
 
 

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