Milling
R&D and Production planning
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Solid Carbide tools play an essential part in the global manufacturing industry. They are used in milling, drilling, tapping and reaming operations for all sorts of products. By constant improvement of the technology inside a tool, we can improve performance, safety conditions and efficiency. The standard recipe for a solid Carbide tool is approximately 90% tungsten carbide, 10% cobalt, and a small amount of a specific metal binder. The result tools made from one of the hardest materials in the world known for their outstanding performance and durability. This is how we make them. It all starts in the research and development department. The R&D team creates a technical specification, and optimized solutions for specific materials and applications for the tool based on manufacturing needs, such as high quality, long and predictable tool life What we try to do is, starting from what are the needs from our customers, try to interpret them and to translate into a technical specification for our products. Building knowledge around all the application and solve the problems. From the idea to the industrialization there are many processes and many activities that we run to make sure to arrive to a launch with the right solution that is consistent and also of course to guarantee high quality in the product. Developing a tool that is both more efficient and safer than any existing product on the market, while also being more sustainable is always a significant challenge. 3D modeling and simulations are used to develop the initial tool design, Simulations are useful for analyzing the physics of the cutting process and can help to eliminate the need for excessive testing and prototyping. This approach is not only sustainable, but also a smart and efficient use of resources. These simulations are very accurate and break down the tool into thousands of nodes, performing millions of calculations to analyze the state of each node during the operation. The simulation captures various factors such as chip morphology, tool temperature and stresses, cutting forces and power. This data enables us to analyze how new geometric features can affect product performance and make informed design decisions. After obtaining the desired results, the first prototype is created. Now it is time to put the tool through some extensive testing. We measure the cutting forces and vibrations in the operation to get real time feedback on the cutting conditions and surface quality. After each test, the tool is inspected and measured in the lab. Advanced measuring techniques such as laser scanning, 3D scanning and image processing are used to achieve a high level of precision that matches the manufacturing and design standards. Using these techniques deviations as small as one micron can be detected as a comparison. A strand of hair has a diameter of around 70 microns. Small changes can make a big difference in tool performance. The data gathered in the lab, along with the test results, is used to optimize the tool design. Then it's back to testing. The purpose of testing is to validate simulation conditions and make necessary adjustments based on theoretical models, by utilizing simulations and data driven analyzes, we can minimize the number of prototypes needed before we ultimately arrive at the final design. In the technical office, we prepare and optimize the production process. I lead a team of six people dealing with machine programing for production, but also involved in the development of new products, with R&D. And also an important part is the design of new production processes. When new technologies are available. And our goal as an engineering department is to to give a program that runs perfectly in the machines so the operators can be sure that the product coming out from the machine is the right one. The design provided by the R&D team is used to develop a simulation program for the manufacturing process of the tool. This allows us to visualize how the tool will look when it comes out of the machine and make necessary adjustments to ensure it's suitable for the production environment. by doing a simulation, I can see a lot of things in the machine, how it goes, how it runs the program. seeing the movement of the axis inside the machine. So in the simulation, I can see that I check everything, I check the cycle time and, the final goal is to send into production a good program that have no issue and also give some instruction how to run it inside the machine. Is there any special operations? So the operator in the workshop, they need to know how to manage that. Once the technical office is satisfied with the simulation results, the program is ready for large scale manufacturing.