MANUFACTURING

Manufacturing

fabrikazioa_argazkiaThe growing demand and evolution of the manufacturing processes along with the integration of the new technologies of Industry 4.0 into the market, with the Additive Manufacturing as one of the fundamental pillars, provide the machine tool industry and its users with a wide range of design and production possibilities.

In this framework, the technical team of TKgune Manufacturing can help you to analyze your current production processes, raising and executing improvement actions to increase your performance (reduction of manufacturing times and costs and improvement of the quality of the final product). We can also simulate operations and alternative processes avoiding interference in your production line and analyze the results to confirm or rule out hypotheses.

In addition, we can help you to plan, design and test totally innovative processes. To do this, in TKgune Fabricacion we can carry out the previous studies including the pertinent tests to confirm the efficacy and stability of the new alternative.

You can manufacture and test prototypes and materials, optimize manufacturing processes and even test the industrialization of the new product with a pre-series using the machines and installations of the training centres that participate in TKgune Fabricacion. Also, we can provide the vision of the machine tool manufacturers regarding the appropriate machinery to manufacture your product.

We encourage and accompany through the innovation of products contributing our technical, technological, productive point of view, and we also put at your disposal analysis of products and creativity tools.

SPECIALIZATION

Manufacture of plastic and metal parts using different AM technologies. Prototyping, repairing of high added value components, pre-series for validation and geometric modification. Scanning for reverse engineering. Specific training. Definition of new productive processes.

High speed and precision machining of several materials: metals, graphite, composites, titanium, Inconel, new materials…
Machining, cutting and shaping processes optimization. Mechanical assembly. Programs (ISO or CAM). Prototypes and trial runs prior to client introduction.

Additive manufacturing with plastic and metal materials.

Mechanical testing and metrology

Material weldability studies. Homologation of welders. Robotization and automation of welding processes.

Tests, study of defectology and material parameters.
Advanced mechanical characterization and general characterization of materials.

Thermal treatment optimisation based on material analysis.

Design and development of products, components, tooling, prototypes and automated cells. 3D scanning and printing.
Design and simulation for structural optimisation using finite elements method (ANSYS).

Process automation solutions. Testing and simulation. Programming of PLCs and associated mechanisms.
Integration with electrical, pneumatic, hydraulic and robot technologies.

Development of communication systems. Monitoring and supervision.

Instrumentation selection. Product verification by means of MMC. Verification and control (computer vision, laser gauges, etc.)

Design and optimisation of cold, semi-hot and hot forging processes.
FEM simulation. Creep, verification of sequences and preforms, detection of defects, creases, filling defects, stringing, etc.

Materials characterisation to create cold forging models.

Design and study of tool life.

Prototyping and first series. Trials on a Sacma SP260 press.

FEM simulation of cold and hot processes. Design of components and tools in different CAD systems.
Verification and digitization of components and tools by means of 3D scanning.

Study-Design and manufacture of tools: progressive dies, etc.

Design, creation, measuring, scanning, manufacturing and testing.
Tests on materials and test sockets by means of the bubble system and their manufacture in carbon fibre and Kevlar.

Welding and metal fabrication in general.
Design and manufacture.

Thermographic analysis, analysis of vibrations, oils, etc.

Android and Arduino development.
Microrobotics and Microelectronics.

Rationalization of processes.
Advice on management systems (EFQM, ISO 9001, OHSAS 18001 safety, the environment ISO 14001, ISO 9100 aviation, welding ISO 3834).

EQUIPMENT

ADDITIVE MANUFACTURING

  • LMD laser metal delivery cell
  • WAAM metal plasma delivery cell
  • SLM metal filler machine
  • 3D printing on plastic materials
  • Scanning

MECHANICAL WORKSHOPS

  • Multitasking
  • Machining centres
  • Production milling machines
  • Turning centres
  • Production lathes
  • Grinders
  • Electrical discharge
  • Robots

LABORATORIES

  • Metrology
  • Mechanical tests
  • Metallography & Materials
  • Industrial automation
  • Process control
  • Optical fibre
  • Telecommunications
  • Transformation centres

CONFORMATION

  • Multi-station mechanical presses for cold forging
  • Mechanical presses for sheet metal stamping
  • Arbor press
  • Threading machines by lamination
  • Hydraulic press for hot and cold stamping

WELDING AND METAL FABRICATION
WORKSHOPS

  • Industrial Maintenance Workshops
  • Automotive workshop
  • 2D cutting: plasma, laser, punching
  • CNC bending machines
  • Welding robot

CAD-CAM-CAE

  • Multiple software options
  • 3D printing

NUMERICAL CONTROLS

  • Fagor
  • Heidenhain
  • Fanuc
  • Siemens

SUCCESS STORIES

In Europe parts are now manufactured for forming in hard metal. One of the companies dedicated to the manufacture and commercialisation of similar pieces but in another material decides to experiment with hard metal. The type of material used is determined and, by means of experiments on the machines at the centre, the turning process required to obtain the desired shape is established and the machining parameters and necessary tools defined.

A company is dedicated to the design, manufacture and commercialisation of machine components (cylinders and hydraulic equipment). To validate the new designs, finite element simulations are carried out and the components are improved applying this method.

A company wants to test the functionality of the tools of the machine it has designed. The tools designed are therefore manufactured and the machining tests carried out, demonstrating their behaviour to the client.

A forging company must go deeper into research on the sequence of a new reference. Different options are analysed by means of FEA and the reference is successfully produced. When more than one viable option emerges, the most profitable alternative for the life of the tools is chosen. As a result, important savings are obtained when making the prototype.

The complete process is analysed with a view to improving the behaviour of the products produced as regards oxidisation. The problems associated to rust and oxidisation are identified and improvements proposed for products manufactured with stainless steel. A series of indicators are established for follow-up of the steps taken, in order to record variations in any part of the production process.

A manufacturing company has the opportunity of an order to produce structures for one of the world’s leading aeronautics companies; however, one of the requirements is friction welding. The company has never used this system. After analysis of the patents and suppliers, tools are designed for welding and, having machined the tools in four geometric configurations (in the first phase), welding tests are carried out on the milling machine until obtaining a process compliant with regulations.

The process of manufacturing a piece requires improvement. Apart from the manual work, the process requires 9 operations to be carried out on 4 different machines. Having drawn the image in 3D and created the CAM program, research is carried out, reducing the process to 6 operations carried out on a single 5-axis milling machine (single joint) and a final cut by means of electrical discharge. The production cost is reduced by 65%.

MULTIMEDIA

PICTURES

VIDEOS

CONTACT

CIFP IMH LHIIElgoibar

Iñaki Alegria

943 74 41 32

tkgune@imh.eus

CIFP BIDASOA LHII Irun

Jose Luis Ormaetxea

943 66 60 10

tkgune@fpbidasoa.org

EGIBIDEVitoria-Gasteiz

Igor Madariaga

945 01 01 30

tkgune@egibide.org

CIFP ELORRIETA-ERREKA MARI LHII Bilbo

Carlos López

944 02 80 00

TKgune@elorrieta-errekamari.com

GOIERRI ESKOLAOrdizia

Xanti Iruretagoiena

943 88 00 62

tkgune@goierrieskola.org

LA SALLE BERROZPEAndoain

Xabier Puertas

943 59 05 57

tkgune@lasalleberrozpe.com

LEA ARTIBAI IKASTETXEAMarkina-Xemein

Xabier Uranga

946 16 90 02

tkgune@leartik.com

CIFP MIGUEL ALTUNA LHII Bergara

Eli Aranburu

943 76 24 91

tkgune@imaltuna.com

OTEITZA LIZEO POLITEKNIKOAZarautz

Iñigo Aranguren

943 11 10 00

tkgune@oteitzalp.eus

SALESIANOS DEUSTO Zumarraga

Jose Maria Vergara

944 47 26 50

jmvergara@salesianosdeusto.com 

CIFP TOLOSALDEA LHIITolosa

Andoni Arraras

943 65 11 47

TKgune@tolosaldea.com

POLITEKNIKA IKASTEGIA TXORIERRIDerio

Angel Lazaro

944 03 40 60

tkgune@txorierri.net

UROLA GARAIKO LANBIDE ESKOLA Zumarraga

Jon Andoni Torquemada

943 72 54 77

tkgune@ugleskola.org

CIFP USURBIL LHII Usurbil

Aritz Zabaleta

943 36 46 00

tkgunefabrikazioa@lhusurbil.eus

ZULAIBAR ARRATIAKO LANBIDE IKASTEGIA Zeanuri

Arkaitz Bernaola

946 73 91 16

tkgune@zulaibar.org