Category: Machining

In metalworking, the chip removal that occurs during turning, milling, grinding, and grinding operations requires the use of cooling lubricant fluids (FLRs) also called cutting oils or metalworking fluids. Such fluids essentially serve two purposes: to cool the machining area, which is subject to overheating due to continuous and severe mechanical stresses; and to optimally lubricate the tool-workpiece contact, to reduce friction and dissipate the heat produced-which can even exceed 1000°.

It therefore seems evident how much and how lubrication-coolant has a direct influence not only on the quality of machining, but also on the life and performance of the machine tool, so much so that it is now considered an integral part of it. In fact, an efficient lubricant makes it possible to work in optimal conditions: it has been estimated that, annually, production downtime related to inadequate systems negatively affects overall company productivity (minus 10 percent).

In order to avoid problems and limit maintenance work on machinery as much as possible, it is absolutely necessary that the cutting fluid-relative to its composition in terms of additives-be appropriate to the type of machining and the nature of the metals used in production. Commercially, there are essentially two types: whole FLRs (which contain no water) and soluble FLRs (to which water is added in varying proportions). The main characteristics to evaluate when choosing the right fluid for your needs are: stability, detergency, shear potential, decay range, and versatility. On the other hand, there are two variables to watch out for.

The first concerns cleanliness, which must be ensured by means of an appropriate filtration system to prevent chips and metal dust from machining or thermal degradation from getting into the fluid. Adequate filtration also serves to avert the danger of biological contamination, by microorganisms (bacteria and fungal species) that, by spreading into the environment in the form of bioaerosols, can cause respiratory and dermatological diseases.

The second variable, however, relates to sustainability. In the last decade-thanks mainly to the efforts of major manufacturers and distributors-there has been a trend toward the increasing use of renewable-based coolants (with vegetable esters instead of hydrocarbons), which pollute less and can be more easily disposed of. Like all process chemicals, lubrorefrigerants are also monitored by the relevant legislation: the REACH (European Regulation concerning the Registration, Evaluation, Authorization and Restriction of Chemicals), which requires the ECHA European Chemical Agency to periodically update the Candidate List, the list of carcinogenic, mutagenic and toxic substances(SVHC substances). Safety Data Sheets (SDSs), which by law must accompany metalworking oils and industrial lubricants, contain all the information essential for proper and judicious use of the product.

The law also establishes procedures to be followed in disposal operations-as FLRs are considered, like most technical fluids, as special waste. In Italy, CONOU Consorzio Nazionale degli Oli Minerali Usati, introduced in 1982 by Presidential Decree, is the first environmental agency dedicated to the collection, management and transformation of used oils from waste to resources. As confirmed by the latest sustainability report released by the organization, The Consortium can be considered a model at the forefront in the international field: while in Europe a share of 60 percent of the used lubricating oil collected is sent to regeneration, in Italy this ratio reaches about 99 percent, and the process is capable of guaranteeing several benefits such as, among all, the reduction of fossil fuel consumption for the production sector and, as a consequence, the reduction of CO2 emissions into the atmosphere.

Compliance with industry regulations, in addition to being the only possible guarantee for safeguarding the health of workers, is therefore a valuable control tool for companies and metalworking shops that intend to operate in compliance, guarantee the highest quality of their manufactured goods and translate the impact of a virtuous system into marginality. Like Piacenza Meccanica, which, through a structured program of investments in technologies, processes and safety, translates its values into competitive advantage.

Precision machining would not be possible without the appropriate technologies, i.e., state-of-the-art machinery assisted by software that enables its full potential to be exploited. The introduction of numerical control in the design and manufacture of mechanical components-whether isolated elements or assemblies to be integrated into other products and production lines-has been, in this sense, an innovation that has completely revolutionized the metalworking industry.

The manufacture of components with CNC lathes and milling machines does indeed bring enormous advantages, measurable on theoptimization of operators'performance, the quality and accuracy of machining, and the reduction of production time and costs. All these factors have a significant impact on business profitability and it seems superfluous to emphasize how important it is to plan and implement investments in this regard.

The reliability of an industry that works for other industries depends a great deal on thereliability of its technologies; but it is also true that having advanced tools without knowing their functionalities in detail and without having an understanding of how to make the most of them and exploit them to the fullest, resets any strategic advantage to zero. In fact, machining precision mechanical components with CNC machinery involves several steps: being able to govern the process in its entirety, from order acquisition to order fulfillment, is the goal of any efficient production.

The steps to be considered involve both the planning and the execution of the work. The starting point is the technical drawing, usually provided by the customer in relation to specific supply requirements. Even in the case of non-standardized and extremely small-volume productions, PiacenzaMeccanica makes replicable, high-precision components, mainly in aluminum alloy or from plastic polymers; the quality of the constituent materials-for example, fine aluminum, with technical characteristics that meet the requirements imposed by even critical industrial productions, such as those in the railway, aeronautical, and hydro-sanitary sectors-combined with experience and method, allow the company to act on technical drawings and improve inaccurate designs.

The drawings, made in CAD - Computer Aided Design language, are examined by the company's in-house design department, which is able to refine and adapt them to CNC machinery. The translation of CAD language into CAM - Computer Aided Manufacturing is what transforms each design into a tangible reality, offering the possibility of simulating the entire machining process in detail. A perfectly executed CAD design must therefore take into account both the tools used and the behavior of the part during its machining. The designer is given leeway to be able to intervene in certain variables that, if properly managed, guarantee an optimal result-such as tolerances, or the rethinking of complex or unnecessary aesthetic features. The experience gained in the field allows PiacenzaMeccanica to draw on a vast pool of expertise and be recognized as an authoritative point of reference and a trusted partner. The historical memory of the company, which has been in business for more than 70 years and is managed today by the second and third generations of the Piacenza family, is an important strength and is perhaps the quality that, more than any other, distinguishes the excellence of the products that bear its signature.

In the landscape of companies dealing with precision CNC machining, the management of quality control of manufactured components is treated in different ways, which depend on the internal company vision and the needs of customers. At Piacenzameccanica, we firmly believe that, even when not required, being able to provide certain attestations is essential in order to provide quality service.

Why choose our company

When we begin to analyze the construction of a component, we create what is called a product sheet: contained within it are the characteristics related to the materials needed to build it (type of material, size, weight, etc.) and the processing cycle. 

Next, the component to be built is divided into processing stages. The first stage is what is called pick up, which refers to the picking up of the raw component from the warehouse and its transportation to the machine. The next stages, on the other hand, involve CNC machining(milling, turning, etc.).

For each type of machining, a control program is applied, which is managed in a computerized way through tablets on board the machine. The first component to leave the machine is analyzed according to a control diagram, within which the measurements to be taken(dimensional, roughness and other types) are established.

Our components are 100 percent verified: all parts that come out have passed a test, inspection, and assessment incorporated into the processing cycle. 

Quality controls are integrated into our system and determined by the ISO certification, which includes a specific way of working and general criteria, as well as customer-specific criteria.

In the railroad industry, where special safety issues must be taken into account, a paper certification is required for each individual component or lot, which must be kept available to the customer for a period of at least 30 years. Everything about the order in question is attested in these documents, whether the information is internal or external to the company. For materials, for example, not only the suppliers are requested, but also certificates with their mechanical properties and chemical composition.

Regardless of requests, our company will process certifications of the materials used and treatments and keep them so that they remain available at all times should the need arise.

Our strength lies in havingcomplete traceability of allprocessing steps and all materials used in the construction of each component-all managed by the company's computer system.

Only in this way can we ensure consistently high quality standards for our customers , continuously improving in terms of efficiency and productivity.

A multipallet machine is a machining center that has two or more pallets on which to clamp components for CNC machining, allowing theoperator in charge to alternate between finished and semi-finished parts without having to stop the machine.

One or more pallets contain the parts being machined at that time. Once one of these is finished, it is deposited in the tooling zone. In this second zone of the machine, theoperator can access it in complete safety, as it is out of range. The operator opens the machine door, replaces the finished part with the part to be machined next, closes the door, and thus begins the cycle again.

During the entire course of these operations, the machine never stops working, and its autonomy is that of the individual component.

The software that handles both machine machining and pallet changing can recognize different components and load the correct one into the execution program to process a particular one. 

Beyond the productivity and functionality that software may have, there is a tendency to choose their homogeneity in different CNC machines so that operators can always work with the same type of interface and thus improve the quality of their work.

Once completed, the finished part is checked in the machine by a probe that takes salient measurements to get feedback on its compliance. If there are any irregularities, the machine can be enabled to change its parameters to make sure that the next part is error-free.

Having more pallets does not automatically mean reducing time, but being able to give the machine autonomy to machine more parts without operator intervention, which significantly reduces production costs and consequently those of finished components.

Why choose Piacenza Mechanics

Our company specializes in custom-made small and medium series production. Within our fleet of machines we have a 6-pallet, 5-axis multi-pallet machine and a 4-pallet, 3-axis machine. 

Since the inclusion of these two machines, we have noticed a marked improvement in product quality and especially delivery time. 

An example is the latest case in which one of our customers in the automation sector needed to order a large quantity of parts to be received with extreme urgency: thanks to our 6-pallet machine, it was possible to deliver the entire quantity in three weeks despite the fact that the forecast called for at least six weeks.

However, as with any type of processing, the machines used are crucial, but it is theexperience of the staff that makes the difference.

Those who use multipallet machines - in addition to knowing how to use them manually - must also be able to program them, so it is necessary to be able to rely on highly qualified personnel both for programming the CNC machine and for checking the finished components. Within the same day, workers have to perform different processes, and this technology is one of the best allies in optimizing their time and consequently the entire production chain, offering customers an increasingly fast, precise and punctual service.

When we talk about assemblies, we are referring to a set of precision mechanical components that are to perform a certain function within the machinery in which they will be integrated. 

Requiring assembled assemblies, as opposed to ordering the individual components that make them up, has significant advantages for companies that need specific equipment for their production. Among the main ones is the ability to interface with a single supplier, reducing risk, time and responsibility. 

An assembled assembly demands many requirements that a company must meet in order to overcome all the obstacles that may be encountered during the production process. First of all, it must be kept in mind that the object to be made will be a unique piece: knowing all the variables related to its purpose presupposes a series of expedients and attentions to prevent problems that may arise later.

This means that you will need to work from aforward-looking perspective, considering all possible assembly and testing problems. Working from knowledge, our company'sprior experience is what can really make a difference. 

The case study

The realization of assemblies assembled, from taking charge of the project to testing, is one of the strengths of our business, as it implies having experience in the use of multiple types of purchasing components, machinery, processing, materials and systems that are used within our company on a daily basis.

In the food industry, for example, assemblies are in high demand for robots, intended for handling products that will become part of production lines. Given their purpose, specific food-certified materials will have to be used, the procurement of which is not always easy.

Why choose our company to make mounted assemblies

Due todecades of experience and a highly trained team, our company is able to produce assemblies composed of extremely heterogeneous mechanical components.

What are the main features that enable us to ensure its comprehensive management?

At the base we have the support of a network of partners geographically close to us (specializing in finishing, painting, galvanic and welding treatments) built with care over time, which makes us proactive in the prevention of any problems. Thanks to our management system, we are able to obtain in the right time the availability of commercial items (such as hardware, actuators, slides, pneumatic and normalized couplings in general) necessary to be ordered for the production of the assembled assembly: this means speed, reliability and adherence to delivery times.

We also boast know-how that is the result of years of work and continuity: behind every machining and every piece of machinery is a professional who has gained a great deal of experience, both at the conceptual and manual level. Together, our team collaborates synergistically in the study of the drawing provided by the customer, in the assembly, in the verification of the correct functioning of the assembled unit and in the eventual modification of non-conforming parts in agreement with the customer, all steps to deliver a perfectly functioning final object.

By choosing to commission a mounted assembly from our company, the customer will receive full availability, technical support and cooperation.