Service

In the workshop, there are two main units equipped with CNC machining centres (horizontal and vertical) and lathes. Additionally, we have an assembly line for switch machines, groups and subgroups. The units are technologically advanced and, able to work independently on composite on composites and complex mechanical parts. With a high degree of automation, they permit a wide range of production and a great deal of flexibility preparing the right time, 24 hours a day. They also drastically reduce downtimes, ensuring a more competitive production. These production systems are managed by our professionally qualified technicians who have been working for the company since leaving high school. Our staff feels and believes in our brand and is constantly focused on achieving the company objectives. Their professional growth is guaranteed by continuous training.

We have following main production systems:

Horizontal milling

4 axis machining centre (FMC)

magazine with 122 tool positions ISO 50

with 11 pallets 630 x 630 pallets

integrated IBM RISC 6000 supervisor

Balluff tool coding and FMX software

CNC D.E. Z32 Systems (X= 800, Y= 850, Z= 900)

Spindle speed 4000 r.p.m

spindle power 28 kW

fitted with Heidenhain digital readout on the X, Y and Z axes

(Producer MCM)

4 axis machining centre (CIM FMS)

magazine with 125 tool positions ISO 50

with 12 pallets 630 x 630

6 additional tables not on standard version

IBM RISC 6000 Line Supervisor, FMX software

CNC D.E. Z32 Systems ( X= 800, Y= 700, Z= 800)

Spindle speed 8000 r.p.m

Spindle power 20 kW

fitted with Heidenhain digital readout on the X, Y and Z axes

(Producer MCM)

4 axis horizontal machining centre

magazine with 199 toll positions with tool changing HSK-A100

pallets 630 x 800

rotation diameter 1400

max. weight on pallet 1500 kg

numerical control CNC Fanuc 16-I; ( X= 1300; Y= 1010; Z= 1100)

spindle 14000 r.p.m. HSK-A100

spindle power kW 69

continuous rotary table with 360.000 indexing divisions

fitted with Heidenhain digital readout on linear and rotary axis

(Producer MCM)

4 axis machining centre

with professional Microcomputer and integrated numerical control CNC FANUC System 16 IM

magazine with 90 die-positions, coupling HSK-A 100

pallets 630 x 630; (X= 900, Y= 800, Z= 970)

spindle unit 20-12.000 r.p.m

electro-spindle with integrated CA and coupling for tool changing HSK-A100

spindle power 30 kW

rotary table with numerical control and 4th axis NC with 360 positions

feed rate 1….50.00 mm rpm

rapid 50.000 rpm

(Producer MAKINO)

Vertical milling

4 axis -ISO 40 CNC palletized vertical machining centre

with 2 pallets 500 x 1000

30 position tool magazine (X= 800, Y= 520, Z= 550

spindle power 26 kW

continuous rotary table

tailstock

(Producer SIGMA)

4 axis vertical machining centre

2 tables of 100 x 770 each

coupled tables 2180 x 770

stroke X= 1000; Y= 810; Z= 630

with coupled tables X= 2140; Y= 810; Z= 630

max weight on one table 1000 kg

on two tables 2000 kg

tool magazine with 50 cone positions HSK-A63

spindle 40-15000 r.p.m/li>

- indexing angular spindle 360000 programmable positions

with pressurized Heidenhain digital readout

fitted with CNC Siemens Sinumerik 840D

(Producer SIGMA)

Turning

• 5 axis CNC turning/milling centre

tool pocket HSK-63 for turning / milling

chain magazine with 80 positions

Max. turning diameter 500 mm

max. turning length 800 m

counter spindle

Milling of teeth

electro-spindle 5.000 rpm

counter spindle 6.000 rpm

contro mandrino

turning/milling spindle 12.000 rpm

(Producer DMG )

5 axis CNC turning/milling centre

tool pocket HSK-63 for turning / milling

chain magazine with 48 positions

Max. turning diameter 500 mm

max. turning length 1.250 mm

counter spindle

Milling of teeth

electro-spindle 5.000 rpm

counter spindle 6.000 rpm

turning/milling spindle 12.000 rpm

(Producer DMG)

Tools measuring device with accessories (presetting)

(Producer SPERONI)

Balancing-machine for tools complete with adapter for cone ISO and HSK

(CEMB)

14 stations CNC

max. L= 560

max. Internal turned diameter = 670

External diameter between points 350

Maximum diameter when rotating 800

spindle power 22 kW

(Different models)

Grinding

CNC Cylindrical grinding machine

distance between centres 1000 mm

centre height 175 mm

max work piece weight 120 kg

(Producer STUDER)

Tangential grinding machine

600 x 300 x 400

Dyaform unit

(Producer BLOHM)

Welding

Welding station with qualified personal (N° employees)

(Producer FRO)

Electric arc welding machine for coated electrodes

(Producer VITECO)

Washing plant

Washing machine L= 4500 mm; H= 2540 mm; depth=1800 mm

(PERO)

Quality Laboratory

CNC three-dimensional measurement machine with statistical processing program;(DEA)

Optic emission 15 analytical channel spectrometer with argon flux sample stand for simultaneous and quantitative analysis, chemical elements in solid samples routine analysis and steel and cast-iron analysis

(Spectrocast)

Magneto scope; (Namicon)

Ultrasound tester; (Namicon)

Durometer; (Galileo)

Surface-finishing testing instrument; (Hommelwerke, Thyssen)

Insulation tester; (Siemens)

Digital tester for springs (draught and compression); (Imada)

Digital multimeter; (Fluke)

Digital feeder mechanism; (Gossen)

Pendulum dynamometer; (Mitutoyo)

Dielectric tester; (Hioki)

Metrology room for primary samples

Measurement and inspection equipment (Gages, Micrometers, Altimeters, Comparators)

Within the production process, besides the highly advanced production systems, particular importance is paid to the study of the cycle, design and manufacture of equipment. So in order to meet the needs of the market, we established a design unit – virtual simulation of both design and technology and advanced production control, integrated with support software:

Solidworks (CAD)

EdgeCAM (CAM)

Design of production equipment and industrialization of product, are controlled by the following activities:

Activity planning and assignment of responsibilities

Data identification and basic requirements

Definition of design res

Inspections, reviews and design validation

Documentation and recording of activities

The company is certified for welding according to EN ISO 15085-2 - CL1 level

The welded products are manufactured using qualified processes according to UNI EN ISO 15613: 2005

Personnel employed for welding is qualified according to UNI EN ISO 9606-1: 2013

Non-destructive testing (NDT) on welds are performed by trained (visual inspection - VT) or qualified personnel in concordance to the UNI EN ISO 9712: 2012 - Level II (penetrating liquids - PT).

Ferraioli is set up to supply products on a full Turn Key basis:

- support to product industrialization

Customer Rolling Forecast Management

sourcing of raw materials and commercial components

fulfillment of the whole production flow, including assembly

fulfillment of control activities with final test and non-conformity management

product delivery to the destination chosen by the Customer

management of buffer stocks in Ferraioli’s warehouse (raw materials, semi-finished and finished products)

There is no doubt that quality acquires a strategic value, when we consider the complexity of the machining. Production processes, are continuously monitored also through frequent periodic audits by our customers. The instruments of the quality laboratory allow us to perform the required dimensional controls, according to both customers and internal control plans.
In a few words, the management of our quality has the following aims:

guarantee permanent conformity of the product to Customers specifications and to the standard UNI EN ISO 9001

continuous improvement of production process

to make responsible all involved business areas.

Awarded Certifications:

UNI EN ISO 9001 since 19955

ISO 15085-2 cl. 1

Following certification are in implementing

UNI EN ISO 9001:2015

TS/16949 (Automotive)

AS EN 9100 (Aerospace)

Forecast of effective achievement: December 2016.

From Trenitalia SpA and other European Rolling Stock producers

Components in different metal materials, obtained by mechanical machining, made from cast, rolled, extruded semi-finished products, for various applications on railway vehicles
Critical and complex products: Axle boxes and lower boxes for wheelsets of railway vehicles
Main mechanical components in steel and cast iron for switch machines P80, MET, MOT
Mechanical accessories for switch machines
Components for railway vehicles gearboxes
Mechanical safety spare parts.

The preservation of the environment, health and safety of its own employees has always been important to Ferraioli & C. We always have tried to avoid that the development and realization of a product, the machine itself or the production process causes risks to the environment, to safety or to health.
We have always been committed to:

the prevention of any form of pollution

continuously improve production process reducing the impact on the environment, on the health of employees and on the safety at work

maintain constructive relationships with the local authorities and administrations, with the aim of generating a close cooperation in order to achieve the best possible results regarding preservation of environment, health and safety at work