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 PRODUCTION EXTERNAL PRODUCTION Heat treatments Structural hardening Degreasing Manufacturing process log Packaging and shipping of products PLCs Vision system cameras Probes CNC automatic turning machines with a sliding headstock «Escomatic» automatic turning machines Coiled material Material in bars Polishing Secondary or complementary operations Galvanic treatments Visual and dimensional inspection by sampling Inspection (full visual inspection) Check Consignment and/or safety stock Chemical polishing Definition and preparation of manufacturing process Feasibility study Simultaneous operations • Drilling • Milling • Polygon operation • Hobbing • Thread-whirling/tapping • Threading • Knurling or frosting • Bending Hardening Tempering Carburisation Polishing Micro-polishing Rolling Frosting Sunray polishing Nickel plating Gold plating Tin plating Rhodium plating Passivation Epilame coating Polishing/ black polishing/ mirror polishing Domed polishing Bluing PVD Sand-blasting and micro-blasting «INTEGRATED MANAGEMENT SYSTEM» (IMS) AS PER STANDARDS: ISO 9001 Global management system IATF 16949 International technical specifications for the automotive industry ISO 14001 Environmental management system ISO 45001 Quality management system for the medical devices industry ISO 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 ersten Werkstücks • Serienproduktion rund um die Uhr an 7 Tagen die Woch • Überwachung der kritischen Masse durch SPC-Kontrollkarten • Wartung von Ausrüstungen und Werkzeugen • Small to large runs • Parts with complex shapes • The material turns on itself and the tools are fixed • Large volumes • Parts with a simple design • The cutting tools turn around the material Machining to create a hole in the workpiece Machining of flat faces, around the periphery or on the faces of the workpiece Hobbing of points or facets (without interrupting the rotation of the material) Machining the teeth on wheels, gears and pinions Machining a screw pitch inside a drill hole Creating a thread along a cylindrical shape Shaping of the material using toothed wheels or diamond-coated rollers Shaping of the shaft of a turned workpiece by bending Solvent cleaning in closed circuit The operation involves heating turned workpieces made from CuBe to approx. 320°C for 2 hours, then cooling them slowly. The material becomes much harder Hardening involves heating steel turned workpieces to between 800 °C and 1000 °C, then cooling them quickly. The material becomes hard and brittle Tempering consists of reheating the turned workpiece for a second time to a lower temperature until it reaches the required hardness Alteration of the peripheral layer of the steel turned workpiece to enable surface hardening The turned workpieces are mixed with carriers, abrasives and additives and then agitated for several hours (or even days) in vibrating bowls The turned workpieces are mixed with carriers, abrasives and additives and then agitated for several hours (or even days) in small bowls Strain-hardening of material using special bell-shaped wheels. Chamfering and brightening of the turned workpieces using etching Formation of surface porosity by scratching with diamond-coated tools, with the aim of increasing the adher - ence of the overmoulded plastic part Small scratches for aesthetic effect, made on the flat face of the machined workpiece, giving a sunray appearance under light Extremely flat polishing of the machined workpiece, giving a mirror effect Polishing and rounding of the machined workpiece edges, giving a mirror effect Oxidation 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 corrosion Depositing a fine layer of any type of material (gold, copper alloys, etc.) by sputtering, primarily for decorative effect for luxury items Blasting a stream of sand or microbeads at high speed onto the surface of the workpiece Depositing a fine layer of nickel on the machined workpiece using an electro - chemical process, to protect it against oxidation Depositing a fine layer of gold on the machined workpiece using an electro - chemical process, for aesthetic effect or for electrical conductivity Depositing a fine layer of tin on the machined workpiece using an electro - chemical process, to increase the workpiece’s weldability Depositing a fine layer of rhodium on the machined workpiece using an electrochemical process, for aesthetic effect Chemical alteration of the surface of the machined workpiece, to reduce oxidation Depositing 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 protocols Visual and dimensional inspection by sampling of the turned workpieces at different stages of manufacture Visual inspection of turned workpieces, 100% of the run • Full automatic inspection for parts of all sizes in large runs • These systems enable to reach in some cases 0 ppm (number of defects per million parts) Control of measurements by image analysis Control of measurements by mechanical probing Automated storage system Delivery 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