agenda - · pdf fileagenda 1 group overview ... since then we have been proudly serving the...
TRANSCRIPT
Who we were – Our history
The 1 st tool-shop
1968Co.stamp was founded back in 1968.A small workshop with few employees, specialized in the manufacturing of die casting dies.
Since then we have been proudly serving the HPDC market, in a costant effort to improve our know-how and expertise .
Who we were – Our history
1968 Foundation
1982 Purchase of first CNC milling machines
1994
1999
2003
2004
2011
2013
2014
2015
2016
2017
First automotive die – Steering Housing
Move to the new premises in Sirone (LC)
Purchase and installation of the 1 st HPDC press, for our internal sampling dept.
Acquisition of 49% of the shares of PAMA SRL
ISO/TS 16949 Certification
Opening and start up of new plant in Rivalta (TO), for plastic injection molds.
New expansion of Sirone plant: rough cutting & drilling facility.
Launch of new dedicated warehouse for finished castings.
Takeover of PiQ2, company that develops simulation softwares.
Horizon 2020 Award.
Coming soon 14001 Environmental certification.
48 CNC milling machines
9 Spark erosion machines
5 Wire erosion machines
6 Grinding stations
6 Drilling stations
4 Turning stations
3 Spotting presses
19 Overhead cranes
Who we are – Sirone plant
Sirone plant - Capacity
440Projects
per year
190New dies,
cavity
replacements 250Modifications,
refurbishments,
Maintenance
7 CNC milling machines
1 Spark erosion machines
2 Spotting presses
2 Grinding stations
1 Drilling stations
3 Turning stations
3 Overhead cranes
Who we are – Turin plant
PLASTIC INJECTION MOLDS
185Projects
per year
59New dies,
cavity
replacements 126Modifications,
Maintenance,
Components
Turin plant - Capacity
11 CNC milling machines
1 Grinding stations
1 Drilling stations
1 Turning stations
3 Overhead cranes
Who we are – Pama plant
MANUFACTURING OF DIE HOLDERS
On-site support
- Auburn Hills, MI -
- Queretaro - - Komaki-city -
Thanks to our partners we
can provide full after-sale
support, on-site:
Engineering changes
Tool repairings
Start-up assistance
Worldwide agencies
Brazil- Indaiatuba, San Paolo -
Ariatech Co. Ltd
Iran- Tehran -
Protos Engineering Co. PVT. Ltd
India- Mumbai -
China Ltd- Shanghai -
North America- Kokomo -
Revenue over the years – in k €
8.50010.400
11.80012.500
14.700
17.200
14.800
17.700
21.800
25.800
31.900
39.700
43.900
49.800
56.000
0
10.000
20.000
30.000
40.000
50.000
60.000
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
2016 Turnover – in K €
30.600
8.800
6.000
4.400
0
5.000
10.000
15.000
20.000
25.000
30.000
35.000
Die Casting Dies Plastic Injection Molds
Foundry Die Holders
Personnel
N° employees of the Group 228
Sirone HQ 168
Turin facility 35
Pama 20
PiQ² 517%
65%
3%
5%3%
3%4%
Design
Production
Administration
Quality
Sales
Purchase
Logistics
Focus on Sirone Plant (HQ)
SANDBLASTING,
DEBURRING & STORAGE (6 )
PM & R&D (6 )
IT (2 )
PURCHASING (5 )
TECHNICAL (18 )
DIE QUALITY (5 )
SALES (6 ) ACCOUNTING (4 )
CAM(3 )
ROUGHING
& DRILLING (15 )
SEMI FINISHING /
FINISHING (21 )
CAM(6 )
PLANNING (1 )FRONT
DESK (2 )
GENERAL
SERVICES(3 )
ASSEMBLY / HOT
SPOTTING (20 )
WAREHOUSE (9 )
CASTING QUALITY (3 )
FOUNDRY
OFFICE (4 )
FOUNDRY (29 )
Employees
Workshop
Offices
168
10.150 m²
1.830 m²
Turn-key service
1. Part codesign
2. Die design
3. Simulation work
1. Complete dies
2. Complete sets of casting inserts
3. Maintenance & refurbishment
1. Samplings
2. Dimensional and metallurgical controls
3. Complete set-up process
4. Process development
5. Production of small batches & special series
Design
HPDC dies
Try-outs / small
productions
Project
management 1. Equipment manufacturing
2. Consultancy service from A to Z
Our goal is to provide our customers with a full package service:
not only the equipment, but complete support during each stage in the
process to the final product.
Project management – from A to Z
What we mean by «die design»
INJECTION
PARAM.LUBRICATION
THERMAL
REGULATION
MATERIAL
and
COATING
CHOICE
DIE DESIGN
Active Vacuum,
Squeezing devices
CAMCAD
DesignOur technical department in Sirone is composed by 24 technicians.
We employ the latest versions of the most important software solutions, availableon the market.
Part co-Design
Working alongside the customer for the preliminary study of the die cast component,
taking into account every single step of the manufacturing process:
Make the die less complex and easier for the user to manage
Optimize component’s features, helping to optimize cavity filling and minimizing porosity
Improve casting trimming by working on the parting lines
Enable easier component workability.
Simulation work – Castle by PiQ²
Note: According to customer needs, we can run simulations with other softwares, available on the market (Magma, Flow3D, Procast), thanks to the good relationships we have established, during the years, with our suppliers.
- Bi-fasic Software (air-aluminum), based
on open-source kernel (Open Foam)
- Accurate calculation of air motion inside
the cavity, flow pattern and effects of
vacuum (see next slides)
- User-friendly interface for die casting
foundries
Co.stamp employes a dual phase simulation software specifically developed for HPDC process.
It is developed by company PiQ² in close cooperation with our R&D department.
Starting from 2016 PiQ² is part of Co.stamp Group.
Castle – some features
Vacuum 80 mbar
No venting
High degree of accuracy in the determination of filling flow pattern.
Manufacturing of dies
Type HPDC dies
Alloy Aluminum Magnesium
Market Automotive
Size From 500t and up to 4500 t HPDC machines
Application Powertrain Structural
Industrial
Application areas: Automotive - Powertrain
Cylinder Head
Cover
Steering housing
Flange housing
Gearbox housing
Clutch housing
Cylinder blocks
Bearing Flange
Shock Towers
Front Crossbeam
Instrument Panels
Bearing Flange
Window Frames
Application areas: Automotive - structural parts
Ladderframe
Cover Cooling Duct
Transmission Housing
Oil Pan
Flywheel Housing
Application areas: Automotive - trucks
a
b
cd
e
f
g
g h
il
b
c
d
e
f
g
h
i
l
Workflow of the steel block
a IN
Roughing & drilling
OUT for HT
IN after HT
Quality inspection of the steel
Semi-finishing and finishing stage
Assembly line
Die-tryout on HPDC presses
Quality inspection of the parts
Machining of the parts
Implementing a codification system which assigns a barcode to each stage of the
manufacturing process allows an accurate analysis of production progress for each single
component, and related costs.
Encoding system
Co.stamp is equipped with an internal foundry department.
Each die casting machine is placed in an automated workstation equipped with:
casting extraction robot, automated lubrication system, cooling tank and trimming press.
3 Complete automated die casting
workstations:
ITALPRESSE 3000t TF
ITALPRESSE 2500t
IDRA 1900t
Die Casting Foundry
1 StrikoWestofen
Furnace
500 kg / h
Melting capacity
2 StrikoWestofen
Furnaces
750 kg / h
Foundry Equipment
Foundry
Equipment
Thermal regulation
with electric system
Blast furnace
Thermal regulation
Spray robot
N°2 feeding lines
Zone / Product2-way and 4-way
Vacuum system
Extraction robot
Alloy treatment +
degassing
Quenching tank
and cooling fixtures
TrimmingThermo camera
Jet cooling – 4 lines Squeeze
Pin System
Casting integrity
sensors
Special
Productions
Foundry
Al HPDC
dies tryouts
Prototype seriesSpecial series
Limited series
(small batches)
Aside a picture of one of our die
casting workstation and an
example of our special
productions.
Process development
Die Casting Foundry
Casting and trimming
Dimensional check through dedicated fixtures
and gauges
Machining
Teflon coating
Delivery to customer for assembly
Case history of special series
Lamborghini Huracan – Rear Grille
Horizon 2020 program
Co.stamp has been awarded by the European Union with the Horizon 2020 funding-
program, for its project named «puzzle die».
Scope
The main objective of this project is the development of a software that allows to
design dies that could last longer in comparison to standard dies.
This is possible thanks to a complete new design-approach, that we have already
tested obtaining outstanding results.
Quality department
1. Alloy analysis (chemical composition, density)
2. Analysis of the casting (CMM, X-ray, Laser scanning)
Casting Quality department
Mold Quality department
1. Die analysis (metrologic, Laser scanning)
2. Steel analysis (chemical analysis, hardness tests)
N°1 DEA 3D CMM machine
Model: GLOBAL
N°2 DEA 3D CMM machines
Model: MISTRAL 100707
N°1 BOSELLO X-ray machine
Quality Dept. – Main equipment
N°2 FARO
laser scanning arms
Part
sAlloy
Cavit
ies
and p
art
s
N°1 SPECTROMAXx for metal
analysis
N°1 ORMA analytical scale for
density analysis
Our internal quality
dept. performs FARO
laser scannings on all
cavities and slides.
(Here a couple of
examples).
FARO laser scannings
Our foundry is equipped with a new Bosello x-ray
machine, that helps us to x-ray parts right after
casted and get immediate results.
X-ray station
Our clients
Partnership – Foundry Star Alliance
Co.stamp is part of the Foundry Star Alliance (FSA), a group of leading companies in their specific
field of activity who decided to cooperate and combine efforts, with the aim of better support to feed
the very rapid growth of the global light alloy HPDC markets.
Door and
windowsFrom 1850 t to 3500 t
Type Dimension Machine
2500 x 2480 x 1350 mm
Door frame
10
Made
Gearbox
HousingFrom 2500 to 3300 t
Type Dimension Machine
1900 x 1960 x 1450 mm 50
Made
Powertrain die
Engine blocks
Engine
blockFrom 2000 t to 2700 t
Type Dimension Machine
2400 x 2380 x 1200 mm 35
Made