How do you make a key?

The key is a mechanical transmission element that allows the rotation of a shaft and hub assembly. The manufacture of a key varies according to the type of Key necessary, but it always involves several manufacturing steps, ranging from design to finishing. In this article, we will show you the general steps for making a key.

Drawing, rolling and shot blasting

The first step in manufacturing a Key Standard is the shot blasting, rolling and drawing of the raw material to give it the final section of the key. This step makes it possible to reduce the size of the raw material to the desired size for Key. At Gardette, we have invested in the know-how of cold steel processing. This equipment allows us to manufacture a wide variety of standard and special steel profiles.

Cup

Once the raw material has been prepared, the key is cut using cutting tools such as saws or milling cutters. This step allows you to cut the Key to the desired length and shape. At Gardette, we are equipped with circular or band saw milling machines. We also have cutting machines with shape milling, in order to make A-shaped keys And C shape keys with record productivities.

Completion

Finishing is the next step in the manufacture of Key. This can be drilling and tapping in milling or simple chamfers in a tank or a slope carried out using numerical control. This step makes it possible to create the grooves, recesses or any other shape that the key needs to remain in position during use. At Gardette we are equipped with plane and double grinding machines, 3 and 4 axis machining centers, traditional milling machines and 2 robotic cells for loading/unloading parts.

Tribofinishing

Tribology is the study of friction, wear, and lubrication. Vibratory finishing makes it possible to apply the principles of tribology through the wear of parts via a mixture of abrasives and passivation liquid. Although often connoted negatively, this wear is necessary in order to guarantee the conformity of our parts to the requirements of our customers. It makes it possible to remove burrs from previous manufacturing processes, to improve the surface condition of the parts and to slightly radiate the sharp edges in order to facilitate the handling and assembly of our Keys. At Gardette, we have two technologies at our disposal to carry out this key step: vibration, which consists in mixing the parts with the abrasives in a vibrating bowl at a defined frequency and amplitude, as well as centrifugation, where the parts are rotated using a rotating bottom. Although centrifugation is the most efficient process, we are limited by the geometry of the parts (deformations, sizes of the parts, inertia due to mass,...).

Treatments

La Key can undergo various types of treatment to improve its mechanical characteristics and its resistance to corrosion and wear. There are 2 types of treatment: heat treatments and surface treatments. Heat treatments make it possible to modify the mechanical properties of parts by modifying the microstructure (for example, tempering + tempering makes it possible to improve the mechanical strength of a part as well as its hardness thanks to the formation of martensite while maintaining a certain maximum elongation depending on the duration and temperature of annealing).

Surface treatments, on the other hand, make it possible to form a protective layer on the steel in order to be able to protect it from the environment of use (for example, zinc plating makes it possible to form a sacrificial anode on the parts for a defined period of time, i.e. the zinc will oxidize instead of the iron contained in the steel in order to protect the part, by first forming white rust (from zinc) and then red rust (from iron).

The quality

From entry into stock to shipping to the customer, raw materials, semi-finished products as well as finished products are systematically checked. When a batch of raw material is received, the steel manufacturer's certificate as well as the dimensions of the lot are checked before the material is validated and recorded in the ERP. During manufacturing, the parts are checked by cross-sampling by the operator, the sector manager as well as the quality department. Before entering stock or being made available for shipment, all production orders are subject to final control by the quality department.

It is during the final control stage that the documents potentially required by the customer are issued (certificate type 2.1, 2.2, 3.1 according to NF EN 10204, measurements, treatment certificate, FAI). We also have the possibility of setting up stopping points, monitoring the capacity of production and measurement resources as well as control plans in order to produce prototype files, complete initial samples (DVI and PPAP level 3).

Logistics and packaging

Once the Key manufactured and checked, it is ready for storage and/or delivery. Packaging is the process of packaging keys in appropriate materials (bag, carton, pallet...) to protect, store and transport them safely throughout the supply chain. It plays a crucial role in the protection of our Keys during storage and transport. At Gardette, packaging respects standards and regulations. We can also adapt according to the specific needs of customers (packaging, cardboard and customer-specific packaging...).

The logistics stage consists in planning the delivery according to the needs and deadlines agreed with the customer. At Gardette, logistics includes several activities, inventory management, tracking orders during production, customer information, transport management and customer returns. This process should be aligned with business goals and take into account budgetary and operational constraints. Good logistics planning improves operational efficiency, minimizes risks and increases customer satisfaction.

Delivery

The final step in manufacturing a key is delivery. La Key is shipped to the customer according to the agreed terms and deadlines. At Gardette, once the key order has been prepared, it is loaded into trucks according to the nature of the goods, the weight and/or the requirements of the order.

Delivery is a key step, in fact, efficient and well-managed delivery can have a positive impact on customer satisfaction, corporate brand image and business relationships.