DEFINITION OF INITIAL PROBLEM
The customer operates in the transmission market for the agricultural sector. Due to the importance of its application, which enables the proper functioning of the mechanical system and prevents dangerous breakage from torque peaks, the customer requires the highest precision of the components.
The pawl, one of the most important elements in transmission system safety, is a component with extremely complex geometry. The critical issues identified by the customer in its suppliers related to cost and production slowdowns, generated by the need to have to rework from machining after the cold forming phase of the component.
The customer approached Pettarini to develop the production process of the component in a more efficient and cost-optimized manner.
How can the production of cold forming components be optimized for subsequent resumption of machining, reducing material waste and ensuring process repeatability?
How can the quality and precision standards of a component produced by cold forming and subsequent machining be guaranteed?
APPROACH
Pettarini plans the production pattern of the pawl by cold forming the wire and subsequent mechanical processing.
A feasibility analysis using a finite element simulator is carried out.
The most suitable materials and necessary equipment are defined.
The cold forming process is planned, studying the compatibility of the subsequent shooting and cold wire stamping processes.
PROPOSAL
Pettarini researches, designs and programs an optimized process for the production of the pawl from cold forming and subsequent resumption of machining. The increased compatibility of the formed product with the subsequent resumption stage ensures the reduction of scrap material and subsequent costs, with an increase in the efficiency of the entire work chain.
Pettarini proposes the sampling of the component. Contextually, each step of process progress is validated by the Quality department.
The result of these activities are the first prototypes made through the new process and design.
4 – RESULTS
WHAT WE HAVE ACHIEVED
The Pettarini solution:
- Generates less waste material, for a greater efficiency overall process;
- It allows for a greater cost-effectiveness of the final product;
- It generates a product that meets the required standards of quality and accuracy and is conforms to the customer’s requirements;
- Properly integrates secondary processing into the production chain.
TO KNOW BETTER HOW WE WORK
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