Profit project is based on creating a new standard manufacturing process for Ti fasteners. The production of Ti fasteners is very expensive and not only because of the raw material price but mainly due to complex production costs.
During the 1st period we focused on the High Speed Hot Forging and Thread Rolling Machines (base of the automation ProFit manufacturing line).
For the Hot Forging Machine, the challenge was to scale up all the features that were tested during the feasibility period. We had to develop a machine able to hot forge, at high speed, up to 12 mm diameters. From simulations performed we learned that a 5 steps machine was enough. This achievement allowed us to design a more compact machine, one tooling kit less, so less expensive for customers, easier to handle, more durable, less maintenance and faster production.
On the Thread Rolling Machine, the most difficult part was related to the heating of the worked rough fasteners. To solve this issue, simulations and testing based on Poggipolini´s hot threading experience, It was possible to achieve the right balance between heating, speed and thread tooling.
During the 2nd period we focused on manufacturing bolts through the Hot Forging Machine and into the Thread Rolling Machine.
We used the Ti coil (wire) as raw material. We put efforts and testings on the equipment to straighten the coil (1st phase of the Hot Forging Machine). In order to understand if the straighten of the coil was key step of the process many tests were done to calibrate the Hot Forging Machine. In parallel we developed a specific set of toolings to produce the bolt in 5 forging steps, balancing the forging speed with the forging temperature of the Ti material. In fact, we are now able to produce 100 bolts per minute within the quality tolerance requirements, before thread rolling, without any machining operations. This means cheaper, shorter lead time, more flexible and better mechanical performance of the bolt itself.
Regarding the Hot Thread Rolling Machine. After the simulations done in the 1st period, testings and different set ups between temperature and speed, we are able to thread roll more than 150bolts/min even more than 200bolts/min for mid size bolts (< M6). This result could allow us to update a new automation layout with 2 Hot Forging Machine and 1 Thread Rolling Machine, if necessary.
Then, the fully automatic inspection machine was properly integrated. This new machine is equipped with 4 High Resolution scanning cameras and 2 Mechanical inspection machines. This means we can test each single bolt produced on the line under 6 fully automatic inspection steps. The goal was to get to a 100% inspection, so each produced bolt goes through inspection machine to provide customers a zero defect supply.
Finally, in order to have one production line to make Ti bolts from wire to packaging, the inspection machine was integrated to the packaging one. So, an automation was created to bring all the bolts after inspection to the packaging area. The packaging machine fills boxes with the number of needed bolts and finally an operator closes the box for shipping.
So, we have built a continuous production system from Hot Forging Machine to Hot Thread Rolling and finally to the Automatic Inspection and packaging system.
