Increasingly complex market requirements are reflected in the technological evolution and manufacturing innovation of Nuova Stame. The whole production process follows rigid stages to guarantee the quality of the finished product. Specialist technicians scrupulously follow each stage.
An essential preliminary stage to start up the whole production process. Initially, we receive the mathematical model of the workpiece, which will become the die. Nuova Stame experts examine the mathematical model to establish all the steps needed and the dimensions of the tooling. After which, the quotation will be formulated for the customer.
In this stage, thanks to the “Methods and Simulations” department, we design and develop the parts that will make up the dies.
The experience of Nuova Stame means that it can use a simulator to virtually create the part provided by the customer. Form this, we will create the method, which forms the basis of the next step: Design.
In this stage, Nuova Stame uses the latest generation programs such as Autoform, Pamstamp, Catia and NX.
Once the method, die type and press on which it will be mounted have been agreed with the customer, we prepare a preliminary layout. To create the layout, Nuova Stame uses a specific program that depends on the customer for which the die is being made.
The available programs are:
The customer provides standards for the die manufacture, which are considered during the design stage. When the design is finished, it is submitted and agreed with the customer before putting it into production.
With production, the stage in which the die material is created starts.
The first processing stage is milling, which involves different operations depending on the type of die to be made: Forming die, drawing die, trimming die, flanging die.
Flattening and 2D machining is carried out on the bases of the castings, using the required machine tools (portal milling machines, travelling column milling machines and machining centres) to perform the milling.
The bases of rolled products are flattened and milled using one of the machine tools mentioned above, followed by grinding the surfaces specified in the design. Finally, it passes on to 2D machining.
The subsequent production stages involve 2D and 3D machining using the same machines as used for the first stage, in addition to high speed milling machines.
Then the various milled parts are assembled together with all the other components, which are available on the market (known as normalised components).
If specified or necessary, a prototype die is made in order to carry out forming tests to verify how the material behaves.
Setting up is one of the key steps of the whole die-making process.
This set-up has proved to be increasingly important over the years, as delicate as it is obscure and complex. This is due to the fact that, during the various tests, it is mainly the expertise, experience and dexterity accumulated by the Nuova Stame technicians over the years that make it so important.
For the personnel in the press department, any modifications, special tricks and adaptations to the tooling during the work are the order of the day. These operations allow the tooling to produce parts with processes that are qualitatively more stable and totally safe. This allows the company to provide tooling that meets the technical and mechanical standards imposed by the various customers as closely as possible.
Setting up consists of two main steps:
The die is completed with all the pneumatic and electrical systems, and is also painted and completed with legends and signs, ready for shipment.
Nuova Stame has 3 coordinate measuring machines (CMM), two of which have automatic movement and one has manual movement. In addition, Nuova Stame has a mobile optical scanning device:
This automatic CMM is used to check most of the medium-large parts; its configuration makes it especially suitable for supports that must be positioned horizontally.
This automatic CMM is used for medium-sized supports in a horizontal configuration, while its two adjoining vertical brackets make it especially suitable for checking elements in the "car position" and therefore with supports that must be positioned vertically.
This manual CMM is used to check most of the medium-small parts; its configuration makes it very versatile, high-performance and fast.
This measuring instrument has a very wide field of application and can be used for all types of parts processed in Nuova Stame, from small parts such as tapers, diaphragms and manifolds, to large parts such as car side panels, frames and various claddings.
In addition to carrying out dimensional checks and reports, it is also very useful for studying vitiation to optimise the quality of the various parts.
The personnel in the Nuova Stame quality control department work in close synergy with the press department, especially during the die test/setting up stage. This is one of the most delicate steps of the die-making process. In fact, it depends on the know-how of the press department personnel, supported by meticulous analysis of the elements that emerge from the various tests.
Obviously, the aim is to achieve a quality standard, in both the tooling and the parts produced, that fully satisfies the needs of the customer.
Once this set-up stage has been completed, the quality control department comes into its own. Thanks to the two stations strategically located in the company, with the help of the measuring machines together with a stock of measuring instruments, the various pre-series samples are measured and certified according to the tolerances and standards prescribed by each customer. The possible types of checks are many and varied, since each customer and car manufacturer has its own procedures to follow and specific forms to be filled in.
Controlling the quality of the tooling does not just mean verifying that the item in question meets the customer's needs as closely as possible, but also that the tooling is able to give the same result for “n” elements. In light of this, statistical studies are carried out on a limited number of elements on specific modules, with the aim of monitoring the stability of a given manufacturing batch of workpieces.
The quality control department not only has synergy with the press department, but also interacts closely with the shipping department, to ensure that the dies are packaged and shipped to each customer.
After shipment, our team of home line tryout experts goes to the customer site to check how the dies made by Nuova Stame operate in the final production cycle. If necessary, appropriate corrections are made to the dies to ensure that the workpiece is repeatable.