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Processes
ENGINEERING R/D
DESIGN AND PRODUCT DEVELOPMENT
OPS technicians carry out on base the customer’s specifications a complete product analysis evaluating critical issues, if the case, and proposing improvements regards to its Quality and productivity, taking care of the part functional requirements.
SIMULTANEOUS ENGINEERING
Through a team activity with the customer using the same parametric CAD software, our specialized personnel identifies the optimal geometrical solutions with particular attention to the part weight. This activity allows reducing modelling times.
CASTING SIMULATION
Casting simulation, analysing also data of temperatures, filling velocity, solid/liquid fraction, air pockets is carried out by means of software PRO-CAST and MAGMA.
COMPLETE THERMAL CYCLE
Casting simulation is carried out with a complete thermal cycle, by including in the calculation the assumed tooling cooling circuits.
PROCESS DEVELOPMENT
The manufacturing process is thoroughly analysed in every phase in order to grant the highest reliability.
RAPID PROTOTYPING, 3D PRINTING
OPS manufactures prototypes in-house.
TOOL SHOP
SERIAL AND SOFT TOOL DESIGN
Design of serial and prototype tools is done by OPS technicians on base their solid experience supported by the use of parametric CAD software.
SERIAL AND SOFT TOOLING MANUFACTURING
Manufacturing of serial and soft tooling is supported by qualified suppliers, instructed to follow the specifications prescribed by OPS. This allows reducing delivery times without jeopardizing the product quality.
SPECIAL SURFACE COATING AND TREATMENTS
Special treatments can be carried out on die-casting and trimming tools in order to improve their efficiency.
ADVANCED THERMOREGULATION SOLUTIONS
Special attention is devoted to the implementation of thermoregulation circuits in tooling, supported by the results of casting simulation with complete thermal cycle.
PRODUCTION
MELTING DEPARTMENT
Melting of aluminium ingots is carried out in dedicated StrikoWesthofen furnaces. Molten aluminium goes through a degassing station with nitrogen in order to reduce the presence of soluted hydrogen.
HPDC CELLS UP TO 2500t
OPS integrated production cells are equipped with die thermoregulation units, possibility of jet-cooling and squeezing, dosing furnace, robotized lubricator, vacuum units, manipulators, trimming machine, control of the injection parameters and thermocamera with display.
HEAT TREATMENT
Furnaces for specific heat treatments to be carried out on aluminium castings are available in-house.
FINISHING, MACHINING AND LEAKAGE TESTS
OPS carries out internally surface finishing operations such as blasting, vibrofinishing and robotized deburring, as well as leakage tests.
QUALITY CONTROL
SPECTROMETER
The chemical composition of incoming material (aluminium ingots) and of material in process (specimen from melting furnaces) is constantly monitored and recorded.
CMMs
Dimensional measurements are carried out on contact CMMs and on 3D optical scanning devices.
X-RAYS AND TOMOGRAPHY
OPS has internal radioscopic cabins provided also with CT (computerized tomography).
DENSITY MEASUREMENT, HARDNESS TEST, ROUGHNESS TEST, MECHANICAL TESTS
Equipment to carry out density, hardness, roughness measurement and mechanical tests are available in-house.
ONLINE PRODUCTION MONITORING
All machineries and plants are linked by means of PLCs to the company database. The collected data are constantly updated and can be anytime displayed on dashboards.
INTEGRATED FACILITY SOFTWARE
OPS integrated proprietary ERP allows all departments, according to the granted rights, to have access to and to manage data and procedures, such as OEE calculation, single piece traceability, plant management, Quality, logistics, maintenance activities, human resources and administration.
OUR INTERNATIONAL REFERENCES
