albertini cesare s.p.a. cesare spa company profile.pdfalbertini cesare s.p.a. is a european company...

Albertini Cesare Albertini Cesare S.p.A.S.p.A.

Aluminum Die-Casting ProductsAluminum Die-Casting Products

General General PresentationPresentation

Albertini Cesare S.p.A. is a

European Company leader in

Aluminium High-Pressure

Die-Casting

andCasting

Who is Albertini?

Machining

offering specific solutions for the

Mechanical Industry

starting from the Design concept

phase to the production of

finished products

Design Concept

Casting

Machining

Finished Products

• 4 Production Plants

• Turate (Como)

• Villasanta (Milan, Italy)

• Cormano (Milan, Italy)

Albertini Main Figures

• Quero (Belluno, Italy)

• Production capacity: 30.000 ton Aluminium Alloy

• Budget Turnover 2015: 100ML€ with 18.000 ton Aluminium Alloy produced

• 660 Employees (2014)

• Quality Certification ISO TS 16949 and ISO 9001

Our DIRECT Customers

Albertini Vision

Manufacturing

of finished

products

Development of

Co-Design and

Technological

Innovation

CUSTOMERCUSTOMERQuality assurance

throughout the

production

process

International

presence to cover

Customer’s

demands

Flexibility to adapt

to Customer’s

needs

CUSTOMERCUSTOMERSATISFACTIONSATISFACTION

New Projects (2012-2013)

Customer: Pierburg

Part: Audi FSI, Ford Puma RWD,

RSA K9K etc. Pump Bodies

Delivery condition: Machined

Quantity: > 1.000.000 pcs/year

Customer: BorgWarner Transmission

Systems

Part: Actuator & Valve Body Fiat DCT635


Quantity: 30.000 sets/year

Customer: BorgWarner Turbo

Part: Compressor Housing Ford 1.5


Quantity: 450.000 pcs/year

Customer: BMW

Part: Rear Housing PL6 AL205

Delivery condition: Raw


Customer: ZF AG

Part: Gearbox Bracket MQB

Delivery condition: Raw

Quantity: 1.000.000 pcs/year

Customer: ZF-LS

Part: VW MQB Steering housing



Customer: ZF AG

Part: Stator



Quero (BL)

Plants & Facilities

Cormano (MI)

Villasanta (MB)

Turate (CO)

2 x 250 t

8 x 600 t

11 x 750 t

5 x 800 t - 840 t

2 x 950 t

10 x 1.100 t

8 x 1.350 t

CASTING MACHINING

60 x CNC Units (1-Mandrel)

40 x CNC Units (2-Mandrel)

14 x Transfer Units (High volume)

10 x Machining Units (specific products)

OTHERS

Sand blasting

Tumbling

RX testing

High-pressure Washing

Leak proof testing

Plants & Facilities

Albertini Cesare S.p.A. can process up to 35.000 tons of

ALUMINUM CASTINGS

8 x 1.350 t

5 x 1.600 t – 1.800 t

10 x 2.000 t – 2.200t

1 x 2.500t

2 x 2.800t

64 Die Casting Machines > 120 Machining Units

Impregnation

Various assembling

> 200 Robots

Plants & Facilities

CormanoCormano Plant (MI) Plant (MI)

Aluminium HP die-casting

Machining

QueroQuero Plant (BL) Plant (BL)


Machining

VillasantaVillasanta Main Plant (MI) Main Plant (MI)

Operation site


Machining - Moulds production

Machining

TurateTurate Plant (CO)Plant (CO)


Machining

Aluminium

furnaces

TURATETURATE

PlantPlant

(Como)(Como)

Plants & Facilities

Finishing

and warehousing area

Die-casting area

(small presses) and machining

VILLASANTAVILLASANTA

PlantPlant

((Milan)Milan)

Machining areas with

High-speed Transfer lines and

robotized CNC Machines

Plants & Facilities

Die casting production

(machines up to 1800 Tons)

Headquarters :

Engineering, Sales,

Finance & Administration

CORMANOCORMANO

PlantPlant

(Milan)(Milan)

Die casting production (big

presses) and warehousing

Machining, impregnation

and warehousing

Plants & Facilities

Big presses up to 2800 Tons

Aluminium

furnaces

QUEROQUERO

PlantPlant

((BellunoBelluno))

Plants & Facilities

New die-casting area (Presses over

2000 Tons), finishing and

warehousing area

Die-casting area

(small presses) and machining

furnaces

Sales Breakdown by Application (2014)

Albertini Products

Automotive (93,0%)

Trucks (2,1%)

Electronics & Telecom (4,9%)

Sales Breakdown by Product (2014)

Raw parts (22,7%)Assembled parts (2,5%)

Albertini Products

Machined parts (74,8%)

Sales Breakdown by Automotive System

Powertrain (14,8%)

Chassis (17,1%)

Engine parts (15,3%)

Albertini Products

Powertrain (14,8%) Engine parts (15,3%)

Power steering (52,8%)

Power Steering System

Customer: ZF-LS (for VW)

Part: Steering housing PQ36



Customer: JTEKT (for Nissan)

Part: Steering housing X11



Customer: ZF-LS (for VW)

Part: Steering housing MQB



Albertini Products


(3 references - 2013)


(2013)

Customer: JTEKT (for PSA)

Part: Servo housing A806



(2012)


(2013)

Customer: ZF-LS (for BMW)

Part: Steering housing X5



(2013)

Customer: Opel-Gm

Part: Clutch housing F13/F17

Customer: PSA

Part: Gearbox housing D4D

Albertini ProductsPowertrain

Part: Clutch housing F13/F17

Delivery condition: Raw part


(2013)

Part: Gearbox housing D4D

Delivery condition: Assembled


(2005 – now spare part only)

Customer: Renault

Part: Gearbox housings (fam.)



(2013)

Customer: BorgWarner

Part: Actuator Body



(2013)

Chassis (Anti-vibration & Brackets)

Customer: Renault

Part: Engine & Gearbox brackets

X70/X76/X84/X85/X90/X91/X95

Customer: AUDI

Part: Gearbox brackets B8

Albertini Products

X70/X76/X84/X85/X90/X91/X95



(2013)

Part: Gearbox brackets B8

Delivery condition:Raw/Machined part


(2013)

Customer: Trelleborg

Part: Brackets & Housings

Delivery condition:Raw/Machined part


(2013)

Engine Blocks and Bedplates

Albertini Products

Customer: IranKhodro

Part: Cylinder block XU7

Delivery condition: Raw part with first

machining and impregnation


(2013)

Customer: PSA

Part: Bedplate DV6

Delivery condition: Raw part with

5 cast iron inserts


(2013)

Customer: PSA

Part: Cylinder block TU1-TU3

Delivery condition: Raw part with first

machining and impregnation


(2012)

Engine Parts

Customer: Volkswagen Customer: BorgWarner

Albertini Products

Customer: Daimler Customer: Volkswagen

Part: Cylinder head cover



(2012)

Customer: BorgWarner

Part: Turbochargers



(2013)

Customer: Pierburg

Part: Oil/Water pumps and covers (fam.)

Delivery condition: Raw/Machined parts


(2013)

Customer: Daimler

Part: Oil-pan OM642 4x4



(2013)

Truck Products - Powertrain

Albertini Products

Customer: Daimler/Mitsubishi

Part: Gearbox housing G131/Fuso

Delivery condition: Raw part – 21,8 kg


(2013)

• Product requirement and function analysis

• 3D Model design

• Finite element Meshing

• Static Analysis

• Modal Dynamic Analysis

• Fit for function design

• Structural optimisation

• Weight Saving

R&D - Co-design

• Stress Analysis

FEM Mesh Static Analysis Modal & Dynamic Analysis

• Fast prototyping (Sand-casting Process)

• Prototyping with Die-Casting pilot moulds

• Mould Manufacturing & Testing

R&D - Tooling

• Development of Casting Model (CATIA)

• Design of the Dies by 3D CAD System

• FEM Casting Simulation (MAGMA)

• Development of Vacuum & Squeeze Systems

• Combined Moulding of Steel & Aluminium

• Measurements by 3D Simulation program

R&D - Casting

• Measurements by 3D Simulation program

In-house

Filling and

Solidification

Simulations

• Development of Machining Fixtures

• Testing of Cutting Tools

• Development of Process on CNC machining units (4-5 axis, 1-2 spindles)

• Specific high volume solutions on Transfer Machines

R&D - Machining

• Development of Automation Concept

• Robot integration (Software and

Mechanical)

• Video camera Check & Feed-back

• Automatic Laser measurement

Control

R&D - Automation

Control

• In-Line Post Process Quality Control

& SPC

• Integration of Leakage Tests and

Assembling processes

• Fully automated Production Units

(Casting, Machining & Assembling

Units)

Quality Policy

Environmental

compliance

Application of

process

methods

Operator

involvement

Quality Certification ISO TS 16949 Quality Certification ISO TS 16949

Focus on

Customer’s

needs

Cost

efficiency

Technological

innovation

QualityQuality

Quality Certification ISO Quality Certification ISO 90019001

albertini cesare s.p.a. cesare spa company profile.pdfalbertini cesare s.p.a. is a european company...

Documents