Initial situation

From a small metal fabrication shop created to bend and weld tubes for FIAT tractors to an industrial hub with over 1000 workers and a dozen companies operating in a variety of industires, from automotive to marine. Today SAG Tubi supplies customers like Ferrari, Audi and Maserati. The plant in Novellara makes 12,000 parts a day of bent, formed, welded and coated tubes for very demanding customers.

Effect

heir old hydraulic machine could not bend some challenging radii. The technological leap forward for SAG Tubi was the introduction of the BLM GROUP all-electric machines that replaced their old bending systems.
Another critical innovation was related to tube cutting using a laser: previously some tubes needed to be transferred from one template to another for finishing operations. With the implementation of, the LT-FREE five-axis fibre laser system, this problem was solved. Now, bent assemblies can be trimmed and finished in one operation.

The solution

The close collaboration with the BLM GROUP began years ago purchasing a B40 tube bending machine and today, with the All-Electric tube bending machine, SAG Tubi can bend tubes with 1 to 1 radius and diameters up to 139 mm and 1.5 mm material thickness. SAG Tubi mainly cuts bent tubes and makes 250 or so different parts every month. When tube diameters span from 4 mm to 150 mm flexibility is required. The most recent purchase was the LT-FREE 3D five-axis laser system. It was the perfect choice for difficult cuts on complicated tubes. The use of a robot to present parts of cutting offers unique performance advantage when combined with the five axis fibre laser head, system flexibility is guaranteed. The machines two work cells provide to ability to process in one station while the other is being set up for the next job. Fibre laser does the rest with cutting speed approximately double that of CO2. The result is that processing time has been exactly halved for some tubes. Having originally started with larger volumes, they are now focusing on using laser because of the huge advantage in addition of not having to reposition parts during processing.

 

The benefits

The initial investment was quickly paid back by the production speed and eas of use without losing accuracy or reliability.

Technical aspects

Fibre laser versatility and flexibility can be exploited to process complex parts efficiently for clean and high-quality results. All-electric bending guarantees maximum accuracy and short cycle times for all radii.