Expertise

Manufacturing process

This infographic shows, in largely chronological order, the different manufacturing steps through which the products pass, as well as all the operations that can be performed at each step, before the finished turned part is obtained.
IN-HOUSE PRODUCTIONEXTERNAL PRODUCTIONHeat treatmentsStructural hardeningDegreasingManufacturing process logPackaging and shipping of productsPLCsVision system cameras ProbesCNC automatic turning machines with a sliding headstock«Escomatic» automatic turning machinesCoiled materialMaterial in barsPolishingSecondary or complementary operationsGalvanic treatmentsVisual and dimensional inspection by sampling Inspection (full visual inspection)CheckConsignment and/or safety stockChemical polishingDefinition and preparation of manufacturing processFeasibility studySimultaneous operations• Drilling • Milling • Polygon operation • Hobbing • Thread-whirling/tapping • Threading • Knurling or frosting • BendingHardening Tempering CarburisationPolishing Micro-polishingRollingFrosting Sunray polishingNickel plating Gold plating Tin plating Rhodium plating Passivation Epilame coatingPolishing/ black polishing/mirror polishing Domed polishing Bluing PVD Sand-blasting and micro-blasting«INTEGRATED MANAGEMENT SYSTEM» (IMS) AS PER STANDARDS:ISO 9001 Global management systemIATF 16949 International technical specifications for the automotive industryISO 14001 Environmental management systemISO 45001 Quality management system for the medical devices industryISO 13485 Occupational health and safety management system• Advanced Product • Quality Planning (APQP)• Creation of drawings from customer projects• Analysis of potential risks (FMEA/FMECA)• Creation of operating procedures• Machine-tool design• Creation of inspection plans• Measurement System Analysis (MSA)Most commonly used materials• Mild steels for automatic machines• Stainless steels• Hardenable, free-cutting carbon steels for automatic machines• Construction steels• Martensitic stainless steels• Austenitic stainless steels• «Copper alloys (CuBe, brass, nickel silver, bronze)»• «Precious metals (gold, palladium alloy)»• Titanium• Misc. (Phynox)Most commonly used materials• Mild steels for automatic machines• Stainless steels• Hardenable, free-cutting carbon steels for automatic machines• Construction steels• Martensitic stainless steels• Austenitic stainless steels• «Copper alloys (CuBe, brass, nickel silver, bronze)»• «Precious metals (gold, palladium alloy)»• Titanium• Einrichten und Validierung des erstenWerkstücks• Serienproduktion rund um die Uhr an 7 Tagen die Woch • Überwachung der kritischen Massedurch SPC-Kontrollkarten• Wartung von Ausrüstungen undWerkzeugen• Small to large runs• Parts with complex shapes• The material turns on itself and thetools are fixed• Large volumes• Parts with a simple design• The cutting tools turn around the materialMachining to create a hole in the workpieceMachining of flat faces, around the periphery or on the faces of the workpieceHobbing of points or facets (without interrupting the rotation of the material)Machining the teeth on wheels, gears and pinionsMachining a screw pitch inside a drill holeCreating a thread along a cylindrical shapeShaping of the material using toothed wheels or diamond-coated rollersShaping of the shaft of a turned workpiece by bendingSolvent cleaning in closed circuitThe operation involves heating turned workpieces made from CuBe to approx. 320°C for 2 hours, then cooling them slowly. The material becomes much harderHardening involves heating steel turned workpieces to between 800 °C and 1000 °C, then cooling them quickly. The material becomes hard and brittleTempering consists of reheating the turned workpiece for a second time to a lower temperature until it reaches the required hardnessAlteration of the peripheral layer of the steel turned workpiece to enable surface hardeningThe turned workpieces are mixed with carriers, abrasives and additives and then agitated for several hours (or even days) in vibrating bowlsThe turned workpieces are mixed with carriers, abrasives and additives and then agitated for several hours (or even days) in small bowlsStrain-hardening of material using special bell-shaped wheels.Chamfering and brightening of the turned workpieces using etchingFormation of surface porosity by scratching with diamond-coated tools, with the aim of increasing the adher-ence of the overmoulded plastic partSmall scratches for aesthetic effect, made on the flat face of the machined workpiece, giving a sunray appearance under lightExtremely flat polishing of the machined workpiece, giving a mirror effectPolishing and rounding of the machined workpiece edges, giving a mirror effectOxidation of the surface of the work-piece in tempered steel by heating to obtain a blue colour, primarily for aesthetic reasons, but also to reinforce resistance to corrosionDepositing a fine layer of any type of material (gold, copper alloys, etc.) by sputtering, primarily for decorative effect for luxury itemsBlasting a stream of sand or microbeads at high speed onto the surface of the workpieceDepositing a fine layer of nickel on the machined workpiece using an electro-chemical process, to protect it against oxidationDepositing a fine layer of gold on the machined workpiece using an electro-chemical process, for aesthetic effect or for electrical conductivityDepositing a fine layer of tin on the machined workpiece using an electro-chemical process, to increase the workpiece’s weldabilityDepositing a fine layer of rhodium on the machined workpiece using an ­ electrochemical process, for aesthetic effectChemical alteration of the surface of the machined workpiece, to reduce oxidationDepositing a microfilm on the machined workpiece to avoid liquid lubricants spreading over the surface when pivoted• Study of process capabilities (Cmk, Cpk)• Creation of test protocolsVisual and dimensional inspection by sampling of the turned workpieces at different stages of manufactureVisual inspection of turned workpieces, 100% of the run• Full automatic inspection for parts ofall sizes in large runs• These systems enable to reach in somecases 0 ppm (number of defects per million parts)Control of measurements by image analysisControl of measurements by mechanical probingAutomated storage systemDelivery according to customer requirements (customised supporting documentation and packaging)• Creation of PPAP (Production Part Approval Process) file• Centralisation of data using computerised ERP (Enterprise Resource Planning) tools
Quickfinder Glossary Manufacturing process

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