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Saen designs and builds diecasting moulds for machines with closing force up to 2.500 tons.
Since 2002 we have had available a foundry laboratory where we carry out samplings, therefore we have developed a deep knowledge of the process, which allows us to support and advise our Customer on all aspects from the diecasting process to the usage of the moulds.
In the manufacturing process of the mould we care for:
Study of the part using the CAD systems in our possession (Creo, Catia, NX): draughts, radii, parting lines, material allowances, tolerances, geometry of the trimming burrs.
Simulation of the diecasting process: using MAGMA we carry out a solidification and filling study besides an analysis of the thermal behaviour of the mould at full capacity.
Complete design of the mould: according to the numerical simulation outcomes we can suggest technical solutions to reach the very best casting results (mechanical, hydraulic, hybrid, special movements, squeeze pins, jet-coolings, chill vents, vacuum systems, temperature control systems for traditional or minimal lubrication).
Machining and assembly: at our premises we carry out all the machining to get components fitting the precision required by the part.
Sampling: we can internally carry out the mould test to verify the seal and closure besides the perfect functioning for the casting, supplying the Customer with process parameters as a reference to start the series production. The thermal behaviour of the mould is monitored using thermographic images given by Marposs Total Thermal Vision.
Dimensional measuring: for the samples produced during the samplings or for spare parts we have available CMM measuring systems and GOM scanning, which allow us to guarantee precision and the obtained results.
At the same time of the diecasting mould Saen designs and manufactures trim dies for presses up to 60 tons closing force.
This allows the Customer to have one single interlocutor and responsible in charge with the data besides the delivery time:
Complete design of the trim dies: according to the results of the analysis of the diecasting mould and the requirements of the component we can suggest technical solutions proportional to the technical equipment of the Customer to reach the best trimming results (mechanical, hydraulic movements, discharge and blowing systems, shot detecting systems to avoid collisions, insertion of operating units).
Machining and assembly: at our premises we carry out all the machining to get components fitting the precision required by the part.
Trimming test: using the shots produced during the sampling we test the equipment to check the perfect functioning. We do this using trimming presses in order to test the real functioning dynamics of the equipment.
Dimensional measuring: for the samples trimmed during the sampling measurements through CMM system and GOM scanning are carried out, which allow us to guarantee that there are no deformations or deviations due to the trimming.
Through the years Saen has developed competences and systems to answer the need of producing prototypes and small series.
We have consolidated experience in the production of prototype tools for samples type A and B and for small quantities which we cast in our foundry lab.
This allows the final user of diecast components to:
Get in 6-8 weeks components which have been produced with the same technology and the same mechanical characteristics of the series production.
Transfer the experience gained with prototyping to the series.
Our foundry lab has available all the technologies and competences to supply parts which are:
Cast
X-rays checked
Trimmed
Sandblasted
Tumbled
Machined
Leakage tested
Dimensionally and geometrically checked through:
CMM
GOM
Digital roughness meter
Through the years Saen has developed competences in the research applied to the diecasting process in international environment, operating inside consortia as a partner or in the B2B perspective as a project leader on specific requirements of the client.
Between 2006 and 2010 Saen is partner of the European project NADIA in which materials and systems for the productive processes in light alloys for the automotive sector are studied and developed. Besides Saen the most authoritative European Universities and research centres as well as the main players of the automotive market cooperated.
Throughout the project Saen develops and manufactures a diecasting mould for the production of diecast test bars for mechanical and chemical-physical tests.
Today this mould available at Saen is part of the European norm PD CEN/TR 16748:2014.
Between 2012 and 2016 Saen takes part in the European project MUSIC where it develops insertion and management techniques of sensors in the diecasting mould to check the production process.
Among the partners European Universities and research centres and the representatives of the technical excellence in the usage and production of diecast components.
Over the years we have built direct cooperations in the development of new technologies and products in B2B scope focused on testing, validating and improving products and technologies for diecasting.
Some examples:
MARPOSS – Total Thermal Vision
Vesuvius – MTS 1500 degassing system