Beyond the Hammer: Taiwan's Advanced Hand Tool Technology

Summary:

■ Highlighting the establishment of the Hand Tools R&D Testing Center and its strategic plan to enhance industry competitiveness.

■ Showcasing four cutting-edge innovations unveiled by the center at IHT x TiTE 2024.

■ Sharing expert insights on Taiwan's hand tools industry and its future outlook.

Alliance for Excellence

To strengthen Taiwan's hand tool industry and counter the intense price competition from Chinese products, a collaborative effort among industry leaders, government bodies, and academic research units has been driving innovation and boosting competitiveness. This joint endeavor began with China Steel Corporation (CSC)—Taiwan’s premier material supplier—teaming up with the Taiwan Hand Tool Manufacturers’ Association (THTMA) to conduct research on international benchmarks, high-value hand tool products, and reverse engineering. Their efforts have yielded breakthroughs in material selection, process technology, and product design, providing significant technological advancements to THTMA member manufacturers.

Building on their earlier achievements, CSC and THTMA expanded their collaborative efforts by leveraging governmental and corporate resources. This initiative culminated in the establishment of the Hand Tools R&D Testing Center in Taichung Industrial Park, a key hub for Taiwan’s industrial innovation. The center's founding participants include the Metal Industries Research & Development Center (MIRDC), CSC, THTMA, and the Corporate Synergy Development Center (CSD). It offers a comprehensive range of services, including materials research, process optimization, lean management, and support with government counseling application procedures for hand tool manufacturers. This strong foundation gave rise to the Hand Tools Competitiveness Enhancement Project, which aims to advance shared technologies and drive innovation across the industry.

At the 2024 International Hardware Expo Taiwan x Taiwan International Tools & Hardware Expo (IHT x TiTE 2024), MIRDC showcased its latest technological achievements in collaboration with CSC. These innovations include:

1. Quenching Heat Treatment Simulation Technology of Steels for Hand Tool Products

2. Application of Simulation Technology

3. Forging Prediction Technology for Hand Tool Products

4. Near Net Shape Forging Technology for Hand Tools

These groundbreaking advancements aim to optimize manufacturing efficiency and elevate product quality across the industry.

In this edition of Taiwan Hand Tools, Dr. Hsu Hsiao-Hung, a Scientist in CSC’s Iron & Steel R&D Department, and Zhang Can-Xun, a Project Engineer at MIRDC, shared insights into the development of these four technologies.

Quenching Heat Treatment Simulation Technology of Steels for Hand Tool Products

The performance of hand tools during quenching heat treatment is often influenced by factors such as product geometry, material composition, quenching temperature, and the chosen medium. These variables can lead to inconsistent results, posing challenges for manufacturers. To address this, the "Quenching Heat Treatment Simulation Technology for Steels in Hand Tool Products" was developed, offering a cutting-edge solution for optimizing the heat treatment process.

This innovative technology employs advanced numerical analysis and specialized software simulations to analyze the intricate dynamics of quenching heat treatment. By enabling rapid evaluation of the manufacturing process parameters, it can significantly reduce reliance on traditional, time-consuming trial-and-error methods.

Marking a breakthrough in the industry, this technology is the first to apply CAE simulation to predict the quenching characteristics of steels. It constructs highly accurate models, including heat transfer coefficient curves, phase transformation models, and hardness models, with precision reaching up to 96%.

Looking ahead, this technology aligns seamlessly with the growing demand for intelligent process design and smart manufacturing. It empowers hand tool manufacturers to implement intelligent heat treatment validation and process design, accelerating new product development and enhancing research and development capabilities.

Application of Simulation Technology

Hand tool production typically involves hot forging and quenching-tempering heat treatment processes to achieve the desired aesthetics and performance. By employing hot forging process simulation, mold designs can be refined to ensure high-precision dimensions and address residual material issues. Additionally, heat treatment simulation technology predicts the strength and outcomes of quenching and tempering processes, ensuring products meet stringent performance standards.

This advanced technology offers a comprehensive solution for process optimization, enabling the industry to evaluate and enhance material savings in hot forging, extend mold lifespan, and fine-tune heat treatment parameters. For instance, using an adjustable wrench made from 40CRV steel as a case study, simulation analysis can optimize hot forging designs and validate heat treatment feasibility. Multiple simulation passes adjust process parameters to assess their impact on the product's geometry and hardness distribution.

Hot forging optimization demonstrates significant benefits, including a 20% reduction in extrusion waste, increasing steel utilization rates to 70%, and lowering mold load by over 20%. These enhancements reduce wear and tear, significantly extending mold lifespan. Heat treatment simulation further predicts hardness distribution with remarkable accuracy, ensuring quenching conditions align with product quality and hardness requirements. The hardness prediction accuracy exceeds 94.2% when compared to actual production results, underscoring the reliability of this innovative approach.

Forging Prediction Technology for Hand Tools

Forging is a critical process in hand tool manufacturing, enabling the creation of complex shapes and high-strength tools. However, domestic forging factories often struggle with mastering the forging process for new materials and product development. This challenge leads to prolonged development cycles and inconsistent production stability.

To address these issues, forging prediction technology for hand tools has been developed. This advanced method integrates material compression testing for hand tool steels with hot forging simulation analysis, establishing a comprehensive digital simulation and prediction system for forging processes. With an accuracy exceeding 90%, this technology provides precise insights into forging outcomes, helping manufacturers optimize their processes.

By adopting this forging prediction technology, domestic hand tool industries can significantly enhance their manufacturing capabilities. It allows for quicker adaptation to market demands, improved production efficiency, and higher-quality output, reinforcing their competitiveness in the global market.

Near Net Shape of Forging Technology for Hand Tools

Traditional forging methods for hand tool production often resulted in excessive burr waste, high defect rates, and labor-intensive post-processing steps. The introduction of Near Net Shape Forging Technology has revolutionized the industry by optimizing forging processes and reducing inefficiencies.

This innovative technology uses digital simulation analysis to determine optimal forging parameters and mold designs before production begins. By employing servo presses and closed forging modules, the material utilization rate can increase dramatically from 50% to 95%. The forged products closely resemble their final shape and size, significantly minimizing the need for mechanical finishing processes.

The technology leverages servo motor-controlled sliders and adjustable forming speeds, allowing for precise adaptation to the unique characteristics of various products. This flexibility is ideal for manufacturing hand tools with complex designs and high precision requirements. It reduces processing time and tooling costs, making it particularly effective for intricate tools like combination wrenches, adjustable spanners, pliers, hammers, and sockets.

Near Net Shape Forging Technology has secured three patents in Taiwan and is widely applied in the production of high-strength, functional hand tools. Its technology transfer to external manufacturers addresses critical gaps in domestic industry capabilities, enhancing product value and independence.

Moreover, the technology supports low-carbon, innovative green manufacturing. By improving material utilization and reducing waste by 45%, it cuts process energy losses by 20%, contributing to sustainable and efficient production.

Crafting Industry's Next Chapter

Highlighting the practical application of Taiwan’s innovative forging technologies, Zhang noted that numerous domestic manufacturers are actively adopting these advancements. For instance, “Proxene Tools”, leveraging material provisions from CSC and CAE simulation and analysis, has significantly enhanced its production efficiency and material utilization. Similarly, “Summer Forging” has embraced material-saving techniques with technical support from the MIRDC, implementing a new production model in its forging plant. Meanwhile, “Johnson Tools” has integrated advanced technologies to establish a modern forging production system, utilizing CSC’s material database to optimize the development and analysis of its socket products and improve asset allocation.

Looking ahead, Zhang analyzed the implications of Taiwan’s declining birthrate and aging workforce, which necessitate the development of automation in the forging sector. Research is underway on robotic arms to replace manual labor, including defect inspections traditionally performed by hand. Image-based detection and process monitoring systems are also under development, representing a step toward smart manufacturing. On the environmental front, while carbon reduction has yet to significantly impact the hand tool industry, many manufacturers are proactively establishing carbon management facilities to prepare for future demands.

Dr. Hsu emphasized that the competitiveness of Taiwan's hand tool industry lies in its mature technologies and extensive experience. However, labor shortages and the retirement of skilled workers pose challenges. To safeguard the industry’s future, preserving and digitally inheriting manufacturing expertise is crucial. Collaboration between CSC and MIRDC, encompassing materials, design, molding, heat treatment, and surface treatments, aims to drive industrial upgrades. Both organizations actively engage with leading manufacturers to provide technical assistance and subsidy opportunities, with goals centered on high value, net-zero emissions, and smart manufacturing.

Taiwan's hardware and hand tool industry has long been a cornerstone of its industrial success, earning international acclaim. The industry has transitioned from mass production to quality enhancement, shifting its focus from price competition to value creation. It has also evolved from simple products to sophisticated innovations, establishing Taiwan as a global hub for high-end hand tool R&D and manufacturing.

Facing intensified international competition and evolving global dynamics, Taiwan’s manufacturers are accelerating their transformation and innovation efforts. They aim to turn challenges into opportunities, maintaining a vigilant outlook while advancing in areas such as R&D, brand building, and strategic business planning. These efforts are essential for preserving the industry’s global competitiveness and ensuring its sustainable development.