Inside Euroricambi Group
We're opening our factory doors to show you how much technology and care to production processes we put into every single gear.
A traveling journey to instill in you our great passion that push us to improve every day and to invest in new production systems to guarantee the highest quality standard.
In our factories, we can perform turning of shafts, gears and sleeves up to diameters of 500 mm.
The shafts are centre-mounted to speed up machining and increase precision by means of tailstocks. Our lathes are automated and equipped with robotic loaders, allowing great versatility and high efficiency even at night.
For turning sleeves, we use machining centres with two spindles that can work simultaneously or in stages. These lathes are also equipped with robotic loaders
We carry out turning for surface finishing with a tool, even on parts that have undergone heat treatment ("hard" turning). In this case we can achieve:
- Surface roughness between 0.6÷0.8 Ra (with theoretical capacity up to 0.4 Ra)
- Increased production capacity
- Zero risk of surface cracks and burns
For internal gearing up to a diameter of 210 mm, we are equipped with 7 broaching machines:
- 4 latest-generation electro-mechanical machines, where the broach (tool) remains in a static position while the workpiece moves;
- 3 traditional hydraulic machines, where the workpiece remains static while the broach moves.
All broaching machines are automated and equipped with robotic loaders that can also work at night.
The tool has a duration that can be calculated in order to schedule machining shifts appropriately.
Broaching is a type of gearing characterised by extreme stability and precision of execution, with much longer tool life than other types of gearing, which also justifies the high costs and achieving high quality parts.
For the execution of bevel gears, our fleet of machines consists of Gleason machines to perform the "Gleason cutting" type.
We are capable of hobbing gears up to a diameter of 1 metre.
The machines have two methods of tooth cutting:
- FACE MILLING - in this case, the tool generates one tooth slot at a time (discontinuous cutting method);
- FACE HOBBING - the tool simulates the engagement between the gear and the tool itself, generating all the slots between the teeth in progression (continuous cutting method).
For external cylindrical gearing up to a diameter of 800 mm and up to module 16.
The fleet of machines mainly includes Liebherr machining centres, which can be:
- gear cutting machines (LS)
- gear hobbing machines (LC)
The machining centres are programmable and equipped with robotic loaders.
Gearing can also be performed on Scudding machines (Profilator Machines), which can perform internal and external gearing up to a diameter of 500 mm.
Scudding machines are fully automated gear cutting machines that perform continuous cutting at very high speeds, thus reducing cycle times and achieving quality parts.
The tool used is very similar to that of conventional gear cutting machines, whose technology in combination with specific materials allows dry cutting (without lubricant). This type of cutting allows the tooth flank to be created according to the required characteristics.
These are machining centres which, thanks to their 5 axes, allow different types of machining to be carried out on the same workpiece.
They are equipped with a Renishaw presetter that allows multiple phased machining operations.
These 5-axis centres also allow gear cutting to be carried out using "Power Skiving" technology, similar to a shaper cutter but with very high cutting speeds.
Several machining centres are available which are dedicated exclusively to the deburring of our parts. They are automated machines. Controlled deburring through a milling cutter is possible using a suitable programme.
Workpiece marking can also be carried out after deburring in these machining centres.
We also have a dedicated machine for deburring carbon fibre synchroniser rings.
On all Euroricambi production processes, starting from blanks to finished parts, we perform various types of checks and inspections of materials, geometries, dimensions and quality of each individual machining operation, including the mechanical characteristics obtainable after heat and surface treatments. We use high-precision equipment and machines for keeping every single stage of the production cycle under control and to guarantee consistent quality capabilities equivalent to the OE.
Euroricambi is equipped with this technology, which guarantees extremely precise and high quality welds. Work pieces can be welded up to a depth of 50 mm, with thicknesses from 0.1 mm to several mm without the addition of material; continuous or spot welding is performed. There are numerous advantages over conventional processes, including high geometric accuracy, homogeneity and uniformity and no inclusions in the welded joints due to the vacuum conditions under which the process takes place, repeatability and speed of execution with resulting reduction in time.
Euroricambi has implemented a heat treatment plant with a capacity of about 20,000 kg of steel per day.
The plant is fully automated and includes 8 electric vacuum casehardening chambers: this technology, compared to traditional systems, allows the deformations to be limited, offering a better quality of the treated material. Quenching (cooling) can be carried out in two different ways, in an oil bath used for larger, thicker parts, and in gas (nitrogen) for smaller, thinner parts.
On the other hand, components with a high risk of distortion, such as synchroniser rings or sleeves up to a maximum of 250 diameter, after being case-hardened and cooled in nitrogen, undergo a new treatment where they are heated by induction and pressurised on the inner diameter through a spindle during the cooling phase (quenching in plug or press).
The grinding department at Euroricambi includes machines for grinding both cylindrical and bevel gears. The department includes radial grinding machines that can perform finishing operations using grinding wheels or tool, or both.
This is a finishing process that can be carried out on components of up to 500 diameter and consists of "shooting" at the surface of the part with a high-speed jet of steel micro-spheres. The impact of the microspheres with the surface layer of the part generates a local compression which increases the surface fatigue strength by up to 20/30% more than a part which has not been shot peened. Another advantage of shot peening is that it reduces the surface tension generated on the surface of the workpiece during previous machining processes.
Molybdenum coating is applied to the synchronisation components. The completely in-house process has a production capacity of around 2,100 pieces per day. The raw product, in the form of molybdenum wire, is melted through a combustion process using hydrogen. The thickness of the molybdenum coating can be adjusted through successive machining steps (grinding, tapping, etc.) and is monitored by dimensional measurements during the process.
High-tech machinery and strict quality control procedures guarantee the reliability and monitoring of the production process. The company has invested considerable resources in the most advanced measuring instruments available on the market, capable of carrying out any chemical, physical and dimensional control on their products. This control is carried out on all production processes up to the finished product: this last quality control is extremely important and requires scrupulous attention because it determines the marketing of the part.