5 quality certification - calvi · 4 the production process ... materials and optimal production...
TRANSCRIPT
www.calv i . i t
CALVI operates according to a quality management system inaccordance with ISO9001:2000 and QS9000 for the automotiveindustry.
An environmental management system is implemented in accordancewith ISO14001 as well as an occupational health and safetymanagement system in accordance with OHSAS 18001.
The CALVI technical department, complete with laboratory, is equippedto carry out the following tests:
•••••
technological tests (hardness, microhardness and tensile tests)chemical analysis (by spectrographic methods)metallographic tests (structure, decarburation and inclusions)non destructive tests (magnetoscopic examination)surface tests (roughness)
Q U A L I T Y C E R T I F I C A T I O N
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CALVI is well equipped with a number of drawing machines forhandling coils and bars, with drawing capacity up to 1.000 KN thuscatering for an extensive dimensional range of profiles.The drawing tools (dies) are designed in-house, together with theuse of F.E.M. simulation systems and are produced on high precisionC.N.C. machines.
Finishing of the profiles is carried out in CALVI onspecially designed lines which allow CALVI to achievevery high levels of straightness.
Cold drawing is the operation whereby one or more reductions in sizeof the semi-finished product is obtained.Such operations, carried out after suitable surface preparation, impart adefinite and constant size to the product with dimensional accuracy asrequested by the customer.
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1 SPECIAL STEEL PROFILES
2 FIELDS OF APPLICATION
2.1 linear guides
2.2 seals for pipe fittings
2.3 automotive components
2.4 woodworking tools
2.5 pumps
2.6 construction of railways and other transport applications
2.7 hydroelectric power stations
2.8 firearms
2.9 slides
2.10 printing machines
2.11 telescopic slideways
2.12 padlocks and security systems
2.13 weaving machines
2.14 knitting machines
2.15 spinning machines
2.16 machine tools
2.17 electric power tools, power saws, lawn mowers
2.18 agricultural power transmissions
3 TECHNICAL CHARACTERISTICS
4 THE PRODUCTION PROCESS
5 QUALITY CERTIFICATION
_1
CALVI was established in 1950 by Otmar Calvi, for the purpose ofmanufacturing special steel profiles with sections of complexgeometry to customer’s specifications. After moving to Merate inthe 1960's, CALVI has now become one of the major companies inthe industrial district of Lecco, an area which is highly specialized inmetal working.
Slideways, frames, ball bearing races, stator support bars for electricalgenerators, pinions, gears, chain pinions/cams, components for firearms:there are many possible applications for CALVI’s special profiles.A highly motivated technical staff is always on hand to deal with individualenquiries from customers.
One of CALVI’s strong points is the capability of designing and building their ownmachinery thus making it particularly suitable for manufacturing profiles of complexgeometry with very high dimensional accuracy.
More than 4.000 shapes already produced testify to the Company’scapacity to meet any type of challenge.
S P E C I A L S T E E L P R O F I L E S
Active co-operation with the Customerin finding solutions to technical anddesign requirements, together with anexperience of over 50 years are the mainfactors lying behind the company’ssuccess. Hence CALVI’s attention isfocused on offering a full service to everycustomer: from technical consultancyin the profile development phase, toidentification of the most suitablematerials and optimal productionparameters in accordance with thecustomer's requirements.
The dedicated machinery and processesapplied by CALVI give the following :
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smooth and clean surfaces
good machinability
elimination of scrap with
consequent raw material savings
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Special profiles for rails and carriers.Steels most frequently used:carbon steels, alloy steels for inductionhardening and case hardening.
Special profiles for inserts in seals.Steels most frequently used:martensitic stainless steels.
2 . 2 S E A L S F O R P I P E F I T T I N G S
2 . 1 L I N E A R G U I D E S
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T E C H N I C A L C H A R A C T E R I S T I C S
Quantities
The flexibility of CALVI’s production machinery allows efficientproductions of special profiles even for small runs.On the other hand, large runs allow optimised set-up times forhot and cold working with consequent advantages in terms ofcost-effectiveness.
The above data are approximate because the thickness and width should be checked
in each individual case in relation to the type of geometry to be obtained.
Dimensions and quality of the profiles
Widths: from 6 to 180 mmThickness: from 3 to 60 mmCross sections: from 25 to 10.000 mm2
Weights per metre: from 0.050 to ~ 75 Kg/m
Bar length
Special profiles can be supplied in bars of different lengths up to amaximum of 10 metres; even on such lengths and with areduced section, a very high degree of straightening is guaranteed.In many cases the above characteristics make a specialprofile the only possible solution.
Dimensional tolerances
Special profiles can be produced with dimensional tolerances of ±0.10 mm, but they can reach a high level of accuracy, such as ISOh 9 and, when requested by the customer, accuracies up to ± 0.02 mm.
Special profiles can be produced in various types of steel: Low and High carbonsteel, case-hardening steel, medium-high alloy stainless steel, aerospace alloys;the range of materials which can be used depends solely on the limits imposedby the deformation properties of the actual steels. Special profiles are suppliedin accordance with the standards requested by the customer: UNI – DIN – AISI –SAE – AFNOR – BS – JIS, etc.
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2 . 1 7 E L E C T R I C P O W E R T O O L S ,P O W E R S A W S , L A W N M O W E R S
2 . 1 8 A G R I C U LT U R A L P O W E R T R A N S M I S S I O N S
Special profiles for splined shafts inuniversal joints.Steels most frequently used:carbon steels and case hardening steels.
Special profiles for pinion hubs in powersaw chains.Steels most frequently used:case hardening steels.
Special profiles for various uses: poleshoes in starter motors, hinges, clutchhubs, components for diesel engineinjection pumps.Steels most frequently used:free-cutting steels or sector-specificgrades.
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Special profiles for toolholders and slideways.Steels most frequently used:carbon steels and case hardening steels.
2 . 3 A U T O M O T I V E C O M P O N E N T S
2 . 4 W O O D W O R K I N G T O O L S
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Special profiles for submersible pump shafts.Steels most frequently used:austenitic and martensitic stainless steels.
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2 . 6 C O N S T R U C T I O N O F R A I L W A Y S A N DO T H E R T R A N S P O R T A P P L I C A T I O N S
2 . 5 P U M P S
Special profiles in bars up to 8 metreslong (seat fastening systems) or inshort lengths (braking systems).Steels most frequently used:carbon steels.
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2 . 1 6 M A C H I N E T O O L S
2 . 1 5 S P I N N I N G M A C H I N E S
Special profiles for support bars andupper aprons in drafting units.Steels most frequently used:carbon steels.
Special profiles for jaws of lathe headstockvices, blocks for work tables and for variousclamping systems.Steels most frequently used:carbon steels, steels for case hardening andhardening/tempering.
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2 . 1 4 K N I T T I N G M A C H I N E S
2 . 1 3 W E A V I N G M A C H I N E S
Special profiles with highly complexshapes, very accurate surfaceswith very close tolerances.Steels most frequently used:carbon steels.
Special profiles for yarn feeder guides.Steels most frequently used:carbon steels.
Special profiles for stators in electricalgenerators.Steels most frequently used:carbon steels.
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2 . 8 F I R E A R M S
2 . 7 H Y D R O E L E C T R I C P O W E R S TAT I O N S
Special profiles used in parts for gunsand pistols.Steels most frequently used:CrMo and NiCrMo steels or gradesaccording to customer’s specification.
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2 . 1 0 P R I N T I N G M A C H I N E S
2 . 9 S L I D E S
Special channel profiles for linear ways.Steels most frequently used:carbon steels for induction hardening.
Special profiles for tensioning guides or for semi-finishedproducts of more complex parts.Steels most frequently used:carbon steels.
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2 . 1 1 T E L E S C O P I C S L I D E W A Y S
Special profile padlock body, gears andparts for automatic door closing systems.Steels most frequently used:carbon steels and case hardening steels.
Special mating channel profiles,profiles for slides.Steels most frequently used:carbon steels and CrMo alloy steels.
2 . 1 2 P A D L O C K S A N D S E C U R I T Y S Y S T E M S
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2 . 1 0 P R I N T I N G M A C H I N E S
2 . 9 S L I D E S
Special channel profiles for linear ways.Steels most frequently used:carbon steels for induction hardening.
Special profiles for tensioning guides or for semi-finishedproducts of more complex parts.Steels most frequently used:carbon steels.
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2 . 1 1 T E L E S C O P I C S L I D E W A Y S
Special profile padlock body, gears andparts for automatic door closing systems.Steels most frequently used:carbon steels and case hardening steels.
Special mating channel profiles,profiles for slides.Steels most frequently used:carbon steels and CrMo alloy steels.
2 . 1 2 P A D L O C K S A N D S E C U R I T Y S Y S T E M S
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2 . 1 4 K N I T T I N G M A C H I N E S
2 . 1 3 W E A V I N G M A C H I N E S
Special profiles with highly complexshapes, very accurate surfaceswith very close tolerances.Steels most frequently used:carbon steels.
Special profiles for yarn feeder guides.Steels most frequently used:carbon steels.
Special profiles for stators in electricalgenerators.Steels most frequently used:carbon steels.
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2 . 8 F I R E A R M S
2 . 7 H Y D R O E L E C T R I C P O W E R S TAT I O N S
Special profiles used in parts for gunsand pistols.Steels most frequently used:CrMo and NiCrMo steels or gradesaccording to customer’s specification.
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Special profiles for submersible pump shafts.Steels most frequently used:austenitic and martensitic stainless steels.
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2 . 6 C O N S T R U C T I O N O F R A I L W A Y S A N DO T H E R T R A N S P O R T A P P L I C A T I O N S
2 . 5 P U M P S
Special profiles in bars up to 8 metreslong (seat fastening systems) or inshort lengths (braking systems).Steels most frequently used:carbon steels.
_9
2 . 1 6 M A C H I N E T O O L S
2 . 1 5 S P I N N I N G M A C H I N E S
Special profiles for support bars andupper aprons in drafting units.Steels most frequently used:carbon steels.
Special profiles for jaws of lathe headstockvices, blocks for work tables and for variousclamping systems.Steels most frequently used:carbon steels, steels for case hardening andhardening/tempering.
2
FI
EL
DS
O
F
AP
PL
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AT
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2
FI
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DS
O
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AP
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_10
2 . 1 7 E L E C T R I C P O W E R T O O L S ,P O W E R S A W S , L A W N M O W E R S
2 . 1 8 A G R I C U LT U R A L P O W E R T R A N S M I S S I O N S
Special profiles for splined shafts inuniversal joints.Steels most frequently used:carbon steels and case hardening steels.
Special profiles for pinion hubs in powersaw chains.Steels most frequently used:case hardening steels.
Special profiles for various uses: poleshoes in starter motors, hinges, clutchhubs, components for diesel engineinjection pumps.Steels most frequently used:free-cutting steels or sector-specificgrades.
_3
Special profiles for toolholders and slideways.Steels most frequently used:carbon steels and case hardening steels.
2 . 3 A U T O M O T I V E C O M P O N E N T S
2 . 4 W O O D W O R K I N G T O O L S
2
FI
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O
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AP
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FI
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Special profiles for rails and carriers.Steels most frequently used:carbon steels, alloy steels for inductionhardening and case hardening.
Special profiles for inserts in seals.Steels most frequently used:martensitic stainless steels.
2 . 2 S E A L S F O R P I P E F I T T I N G S
2 . 1 L I N E A R G U I D E S
_11
T E C H N I C A L C H A R A C T E R I S T I C S
Quantities
The flexibility of CALVI’s production machinery allows efficientproductions of special profiles even for small runs.On the other hand, large runs allow optimised set-up times forhot and cold working with consequent advantages in terms ofcost-effectiveness.
The above data are approximate because the thickness and width should be checked
in each individual case in relation to the type of geometry to be obtained.
Dimensions and quality of the profiles
Widths: from 6 to 180 mmThickness: from 3 to 60 mmCross sections: from 25 to 10.000 mm2
Weights per metre: from 0.050 to ~ 75 Kg/m
Bar length
Special profiles can be supplied in bars of different lengths up to amaximum of 10 metres; even on such lengths and with areduced section, a very high degree of straightening is guaranteed.In many cases the above characteristics make a specialprofile the only possible solution.
Dimensional tolerances
Special profiles can be produced with dimensional tolerances of ±0.10 mm, but they can reach a high level of accuracy, such as ISOh 9 and, when requested by the customer, accuracies up to ± 0.02 mm.
Special profiles can be produced in various types of steel: Low and High carbonsteel, case-hardening steel, medium-high alloy stainless steel, aerospace alloys;the range of materials which can be used depends solely on the limits imposedby the deformation properties of the actual steels. Special profiles are suppliedin accordance with the standards requested by the customer: UNI – DIN – AISI –SAE – AFNOR – BS – JIS, etc.
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CA
L
CH
AR
AC
TE
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ST
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FI
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O
F
AP
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_1
CALVI was established in 1950 by Otmar Calvi, for the purpose ofmanufacturing special steel profiles with sections of complexgeometry to customer’s specifications. After moving to Merate inthe 1960's, CALVI has now become one of the major companies inthe industrial district of Lecco, an area which is highly specialized inmetal working.
Slideways, frames, ball bearing races, stator support bars for electricalgenerators, pinions, gears, chain pinions/cams, components for firearms:there are many possible applications for CALVI’s special profiles.A highly motivated technical staff is always on hand to deal with individualenquiries from customers.
One of CALVI’s strong points is the capability of designing and building their ownmachinery thus making it particularly suitable for manufacturing profiles of complexgeometry with very high dimensional accuracy.
More than 4.000 shapes already produced testify to the Company’scapacity to meet any type of challenge.
S P E C I A L S T E E L P R O F I L E S
Active co-operation with the Customerin finding solutions to technical anddesign requirements, together with anexperience of over 50 years are the mainfactors lying behind the company’ssuccess. Hence CALVI’s attention isfocused on offering a full service to everycustomer: from technical consultancyin the profile development phase, toidentification of the most suitablematerials and optimal productionparameters in accordance with thecustomer's requirements.
The dedicated machinery and processesapplied by CALVI give the following :
•
•
•
•
1
SP
EC
IA
L
ST
EE
L
PR
OF
IL
ES
smooth and clean surfaces
uninterrupted orientation of the
structure
good machinability
elimination of scrap with
consequent raw material savings
T H E P R O D U C T I O N P R O C E S S
_12
4
TH
E
PR
OD
UC
TI
ON
P
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SS
CALVI also boasts state-of-the-art equipment for heat treatment ofmaterial in the rolled state or between subsequent drawing operations.Such equipment is designed to ensure constant monitoring of theatmosphere in the furnace chamber and of all process parameters.
In many cases the first phase in the production process consists ofhot rolling. Plastic deformation is performed by passing the stock athigh temperature through pairs of rigid, counter-rotating rolls.CALVI has two innovative hot rolling mills to cover the entiredimensional range so that high levels of productivity and closedimensional tolerances can be achieved.The rolling mills have the back-up of an internal tool making departmentequipped with C.N.C. machines, thus reducing product deliverytimes and ensuring great flexibility within the department.
The manufacture of special profiles is backed up in CALVI by anin-house developed plant engineering facility, with leading-edgefeatures and great flexibility.
The machinery of which Calvi boasts, together with the experienceof its technical staff and support of the latest design andsimulation tools, allow highly competitive engineering of theproduction process over a wide range of products.
At CALVI there is a continuous commitment to process innovationby continuing a long presence in the iron and steel industry,also in the design of rolling mills and drawing machines.The result is constant additions to their know-how in hot and coldforming techniques.
_13
4
TH
E
PR
OD
UC
TI
ON
P
RO
CE
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CALVI is well equipped with a number of drawing machines forhandling coils and bars, with drawing capacity up to 1.000 KN thuscatering for an extensive dimensional range of profiles.The drawing tools (dies) are designed in-house, together with theuse of F.E.M. simulation systems and are produced on high precisionC.N.C. machines.
Finishing of the profiles is carried out in CALVI onspecially designed lines which allow CALVI to achievevery high levels of straightness.
Cold drawing is the operation whereby one or more reductions in sizeof the semi-finished product is obtained.Such operations, carried out after suitable surface preparation, impart adefinite and constant size to the product with dimensional accuracy asrequested by the customer.
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1 SPECIAL STEEL PROFILES
2 FIELDS OF APPLICATION
2.1 linear guides
2.2 seals for pipe fittings
2.3 automotive components
2.4 woodworking tools
2.5 pumps
2.6 construction of railways and other transport applications
2.7 hydroelectric power stations
2.8 firearms
2.9 slides
2.10 printing machines
2.11 telescopic slideways
2.12 padlocks and security systems
2.13 weaving machines
2.14 knitting machines
2.15 spinning machines
2.16 machine tools
2.17 electric power tools, power saws, lawn mowers
2.18 agricultural power transmissions
3 TECHNICAL CHARACTERISTICS
4 THE PRODUCTION PROCESS
5 QUALITY CERTIFICATION
www.calv i . i t
CALVI operates according to a quality management system inaccordance with ISO9001:2000 and QS9000 for the automotiveindustry.
An environmental management system is implemented in accordancewith ISO14001 as well as an occupational health and safetymanagement system in accordance with OHSAS 18001.
The CALVI technical department, complete with laboratory, is equippedto carry out the following tests:
•••••
technological tests (hardness, microhardness and tensile tests)chemical analysis (by spectrographic methods)metallographic tests (structure, decarburation and inclusions)non destructive tests (magnetoscopic examination)surface tests (roughness)
Q U A L I T Y C E R T I F I C A T I O N
5
QU
AL
IT
Y
CE
RT
IF
IC
AT
IO
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