About splitting (Warisaki®)
About splitting (Warisaki®)
Warisaki® is a revolutionary technique that uses press molds to split metal materials into two or three pieces, enabling the creation of complex three-dimensional shapes that cannot be manufactured using conventional metal pressing methods.
We have also received high praise from a wide range of industries, including the automotive industry.
There are a total of five different processing methods for Warisaki®.
It can actually be split from A to B in one process.
Benefits of introducing the Warisaki® method
Complex three-dimensional shapes that previously could only be produced by machining, forging, or die casting can now be manufactured using progressive metal processing.
Case 1: Integrated molding technology for complex three-dimensional shapes
Since it can be manufactured as a single piece, there are no joints, which increases strength and reduces costs by eliminating unnecessary materials.
Case 2: Joining different metals using Warisaki®
By inserting the connecting material into the split sections and joining them together, the contact area is doubled compared to conventional products, increasing product strength.
Scope of application
Thickness
0.5mm～25mm
* The above plate thickness can be divided into two or three sections.
Materials
Iron
- Iron
- ：SPCC SPHC SPCE
- Galvanized steel sheet
- ：SECC SEHC SGCC
- Tool steel
- ：SK5
- Super Dyma
- ：ZAM
- High-tensile steel plate
- ：SAPH SPFH
Non-ferrous
- Stainless steel
- ：SUS304 SUS316 SUS430 SUS420J2
- Aluminum
- ：A1100 A1020 A5052 A2027
- Copper, copper alloy
- ：C1100 C1050 C5191
- Brass
- ：C2801 C2680
Introduction of each processing method
Warisaki® processing method
Warisaki® is a processing technology that creates shapes by “splitting and tearing” metal (plates, coils, rods) inside a press mold. This is a revolutionary technique that enables the production of complex three-dimensional shapes that cannot be manufactured using conventional metal pressing.
- Product examples
- T-shaped metal fittings
Applications and examples of use
case 1
Board terminals (external input/output check pins for small surface mount boards)
BEFORE
Press the pin into an L shape.
When soldering, the position is unstable and the connection strength is insufficient.
AFTER
Processed using the Warisaki® method
(Original material: Copper t = 0.5 mm divided into T-shaped pieces of 0.25 mm each)
Achievements
1
Improved stability with T-shaped structure
2
Improved connection strength
case 2
T-shaped metal fittings (T-shaped structure for improved stability and connection strength)
BEFORE
①
②
① Press molding
② Welding
AFTER
Processed using the Warisaki® method
Achievements
1
Reduction of labor hours
2
Cost reduction (50% or more)
3
Improved strength and quality without welding
case 3
Exhaust stay
BEFORE
2-piece welding
AFTER
Processed using the Warisaki® method
Achievements
1
Single piece
2
Improved strength and quality without welding
case 4
T-shaped metal fitting with protrusions
Proposed as a positioning bracket.
Achievements
1
Improved stability with T-shaped structure
2
Improved connection strength
Product examples
- Purpose：
- Warisaki® basic shape
- Materials：
- Stainless steel perforated plate
- Feature：
- Thickness: 3 mm
- Purpose：
- Connector receptacles, caps, etc.
- Materials：
- Copper
- Feature：
- One-piece cylinder formed from sheet material
- Purpose：
- Fixing and heat dissipation of cylindrical batteries for hybrid vehicles
- Materials：
- Aluminum
- Feature：
- Warisaki® for extruded materials
- Purpose：
- Busbar joints for heavy electrical equipment, etc.
- Materials：
- Copper
- Feature：
- High-current circuit connections
- Purpose：
- Heat sinks
- Materials：
- Aluminum
- Feature：
- Prototype proposals to overseas manufacturers
Peripheral splitting
Peripheral splitting is a processing method that applies the Warisaki® method to split the outer circumference of round materials and pipe materials.
- Product examples
- Motor cases, air conditioner piping, radiators, waterway piping, etc.
Applications and examples of use
Periphery is machined during the process
Photos showing the peripheral splitting from left to right.
Material: Stainless steel
Three-dimensional shape made by peripheral splitting a single sheet
Shape: Outer circumference approx. 60 mm
case 1
Small motor housing
BEFORE
(1) Casting / Forging + Machining
(2) Bracket installation
(3) Welding (2 pieces)
AFTER
One piece due to peripheral splitting
Achievements
1
Reduction of labor hours
2
Cost reduction
case 2
Connector (USB Type C)
BEFORE
MIM manufacturing method (metal powder injection molding)
AFTER
Made using peripheral splitting
(Waterproof)
Achievements
1
Reduction of labor hours
2
Cost reduction
case 3
Motor bus bar
- 1 Blank
- 2 Drawing
- 3 Punching
- 4 Warisaki®
Achievements
1
Single piece
2
Improved strength and quality without welding
case 4
Aluminum pipe connections
Can be securely fixed by molding to the shape of the other part.
Achievements
1
Improved positioning
2
Improved solderability
3
Reduction in material costs
case 5
O-ring retainer
Example of a proposed component for a transmission oil cooler.
Changed the processing of O-ring grooves from machining to pressing. Prevents O-ring slippage with the peripheral splitting method.
Product examples
- Purpose：
- Joint parts
- Materials：
- ERW pipe
- Feature：
- The welded surface doesn’t crack and splits cleanly
- Purpose：
- Automotive parts
- Materials：
- Round bar (copper)
- Feature：
- Proposal for conversion from machining to peripheral splitting and pressing
Internal splitting
Internal splitting is a processing method that applies the Warisaki® method to split the inside of a workpiece.
- Product examples
- Connector sockets, suspension arms, etc.
Applications and examples of use
case 1
Suspension arms
BEFORE
To increase partial strength, the plate thickness was increased by forging.
AFTER
Partial strength improvement by applying Warisaki® work hardening.
Achievements
1
Reduction of labor hours
2
Cost reduction
3
Reduction in material costs
Product examples
- Purpose：
- Consumer components
- Materials：
- Brass
- Feature：
- Proposal for conversion from machining to internal splitting and pressing
Split joints
Split jointing is a processing method that applies the Warisaki® method to join a split product with another product. It is now possible to reduce the number of processes required for joining parts made of different metals, which was previously difficult, and for joining parts that required screw fastening.
- Product examples
- Bus bars for vehicles, etc.
Applications and examples of use
Conventional technology
Pressing + connecting work
“Warisaki®” technology
Integrated molding using the Warisaki® swaging process technology
Product examples
- Materials：
- Copper – Copper
- Feature：
- Split joints
- Materials：
- Aluminum – Copper
- Feature：
- Split joints
Verification data
| Subject | Item | Specifications (target) | Result | Evaluation |
|---|---|---|---|---|
| Improved precision of Warisaki® processing technology | Splitting precision | ±0.03mm | ±0.02mm | ◯ |
| Durability | Mold life: 100,000 shots (Decide after 5,000 shots) |
Currently 12,000 shots | ◯ | |
| Different metal swaging method | Cross section observation | Confirm metal-to-metal contact | Welding confirmed(Cu-Cu)(Cu-Al) | ◯ |
| Tensile test | 50% or more of the base material strength | (Cu-Cu) Base material strength 5040 N vs. 4790 N (95%) – 4690 N (93%) | ◯ | |
| （Cu-Al）Base material strength 3159N vs. 3120N（99%） | ◯ | |||
| Vibration test | 100m/S2 48h 167Hz | Cu-Cu:17% decrease in tensile strength compared to initial value (3960N) Cu-Al:11% decrease in tensile strength compared to initial value (2810N) |
◯ | |
| Heat cycle | -40〜105°C Maintain for 30 minutes 1,000 cycles |
Cu-Cu:12% decrease in tensile strength compared to initial value (4150N) Cu-Al:1% decrease in tensile strength compared to initial value (3130N) |
◯ | |
| Conductivity test | 400A/14V Temperature increase of less than 50°C |
100 A/1 min when current is on Cu-Cu Temperature increase: 8°C Cu-Al Temperature increase: 7°C |
◯ |
Midway splitting
Midway splitting is a method of splitting sheet metal from the middle using the Warisaki® method.
- Product examples
- Covers and cases
Applications and examples of use
case 1
Covers and cases
BEFORE
Cutting is required in the middle of the case, but punching is not possible due to waterproofing/EMI requirements.
AFTER
Waterproof construction is achieved by splitting the sheet in the middle.
Technical verification data
Residual stress evaluation
Crack condition at the end of the splitting
T-shaped metal fitting tensile strength test
Internal splitting hardness test
Analysis of aluminum pipe cracks, etc.
Split joint verification data
Frequently asked questions about Warisaki®
Q
Can you also handle prototyping and development?
A
Leave everything from single-item prototyping to mass production prototyping to us.
We propose manufacturing processes and VA proposals based on your specific drawings, and propose manufacturing that pursues QCDDS.
Q
Are there any strength or technical data available?
A
Yes, there is. Please see the technical verification data on this page.
In addition, we can conduct various tests according to customer requests.
Q
How is the splitting precision?
A
Our measurements achieve a precision of ±0.02 mm.
Q
What is the maximum length (depth) of the Warisaki® splitting?
A
The maximum processing length of Warisaki® is determined by the die height of the press and the Warisaki® shape.
Please contact us with your desired length and shape.
