Optimization of CNC Machining Processes and Tooling Costs for the Production of Monocoque and Bodywork of the Lamborghini Revuelto

This thesis investigates the optimization of CNC machining processes and tooling costs for the production of the monocoque and bodywork components of the Lamborghini Revuelto. The work was conducted in collaboration with the Technology Division of Automobili Lamborghini and focuses on reducing machining times, improving tool life, and implementing cost-effective strategies for the eight CNC machines and robotic cells involved in manufacturing the vehicle’s components. A comparative analysis between different machining platforms was performed to assess performance in terms of cycle time, flexibility, and saturation capacity under varying production rates. In parallel, strategies for process improvement were introduced, such as the integration of digital monitoring software, optimization of tool paths, and tuning of feed rates at machining exit points. Furthermore, tooling cost reduction was achieved through the implementation of systematic cutting tool re-sharpening, leading to tangible economic savings. The study also includes a market analysis aimed at identifying reliable suppliers for cutting tools and reconditioning services, combining technical requirements with long-term procurement strategies. The impact of these optimizations was quantified through time surveys and weekly production planning under different production scenarios. The results show measurable improvements in machining time efficiency and tooling longevity, leading to a reduction in overall production costs. The introduction of re-sharpened tools, in particular, proved to be a key factor in enhancing sustainability by minimizing waste and resource consumption. While the results are specific for the Revuelto production line, the proposed methodology and strategies are adaptable to other high-performance manufacturing environments.