Journal EDITIO N
2017 / 2018
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MATRIX 10 0 0 |
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➜ Breton
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Mould & Dies best-in-class
➜ Breton ULTRIX 120 0 E VO |
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Doubled working area with 30% less footprint
➜ Breton CO N N E C T TO T H E I N D US T R I A L R E VO LU T I O N | Page 36 The Apps you were looking for
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Machine Tools
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AUTOMOTIVE ➜
Bre t o n R E N A U L T T E C H N O L O G Y L T D .
RENAULT SPORT FORMULA ONE TEAM CHOOSES BRETON AS TECHNICAL PARTNER
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After 40 years of success in Formula One, both as a Constructor and as an engine supplier, in 2016 Renault decided to return to Formula 1 with their own team and Renault Sport Formula One Team began their journey to become a Championship Contender. Time is critical in F1 and there is no room for error: race cars require precision, technical and operational excellence; this is why, as part of their effort to improve their competitiveness, Renault Sport Formula One Team selected Breton as a technical partner. Ian Pearce, Head of Production at the team’s chassis Technical Centre in Enstone, England, says: “Our aim is to improve consistency and accuracy. We chose Breton because their machines can grant this high level of precision while improving lead times. Their accuracy envelope is so wide we can utilize them to machine
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the largest composite components such as the floor and chassis but also smaller car details such as electrical boxes. The chassis in particular represents the very core of the car and the precision with which it’s produced has positive repercussions on everything else.” The accuracy of Breton machines is so precise it enables Renault Sport Formula One Team to machine key components, in just one setup operation. In fact, what is noteworthy about Formula 1 is that cars are almost entirely redesigned and built every year in order to respond to changing regulations and engineering improvements. Production time and flexibility are critical in race car part manufacturing and this is why Breton machines are conceived to dramatically reduce setup operations, which allows the operator to quickly pass from one part to another.
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Machine Tools
R E N A U LT T E C H N O LO G Y LT D.
Breton
Utilizing touch probe systems and dedicated inspection software, Breton machines can automatically locate and reference the parts in the working area, perform a ‘best-fit ‘and provide in-process measurement. This achieves desired DRIFT (Do It Right the First Time), a very important aspect especially when the F1 season is in full swing and the team is calling for quick reactions. The integrated self-calibration feature provides the operator the necessary confidence that the machine is in the optimum condition with no compromise to tolerances. Breton’s Matrix series has always been ahead of the race for accurate prototyping in mould applications, as it offers a wide range of technical solutions to optimize products in surface finish and cycle time. Renault Sport Formula One Team will also use Breton machines to produce their moulds and carbon fibres components. As Renault Sport Formula One Team’s Head of Production confirms: “another application will be the production of tooling such as moulds and patterns. A pattern represents the very beginning of the manufacturing process of every composite component and even a small inaccuracy can have negative consequences on car performance and/or reliability”. An essential requirement in race-car manufacturing is that each part comes out of the machine with the exact parameters specified by its designer; accurate machining centres are essential to give engineers the confidence that components will perform as they expect. Renault Sport Formula One Team has built a brand-new, bespoke Breton facility at their Enstone headquarters to host two new high performance five-axis Matrix 1500 DY K30 gantry type machining centres: “The first project is to host two new CNC machines which require an entirely new 260sqm,almost nine-metre-high building. These state of the art CNC machines are sizably bigger than their predecessors and will serve to increase the capability in terms of both number of components and their size, whilst also greatly improving accuracy”.
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MOULD & DIES ➜
Bre t o n
BRETON FOR HIGH QUALITY MOULD & DIES
Accuracy, reliability, flexibility
The German mould maker, WFT Werkzeug- und Frästechnik, has invested in Breton milling solutions. Specifically, in the recent Flymill HD for machining superalloy, steel and aluminum parts with complex three-dimensional shapes.
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Founded in 1997, but with a company history started in 1919, WFT Werkzeug- und Frästechnik is a German company that manufactures matrices and moulds for punching, foaming and compression moulding of all kinds for the automotive, aerospace, medical and energy industries. Since three years ago, WFT is relying on machines supplied by Breton. Currently the company’s plant houses a Breton Matrix 1000, with axis stroke of 2200 x 2500 x 1000 mm, and a new Flymill HD with head change and an axis stroke of 8000 x 3500 x 1300 mm.
The target industries for the moulds made by the German company impose high quality standards. “Quality is our watchword”, confirms the technical department, “and many years of experience and the constant training given to our engineers and experts guarantee the highest quality combined with reduced production times. To ensure excellent quality, every aspect of all moulds and machines is tested before being delivered to the customer. Moreover, visual inspection is an effective method, but it is not enough to meet the current requirements imposed by the manufacturers of components for the automotive and aerospace industry.
For this reason, we rely on complete control systems and we manufacture measurement devices and test equipment from aluminum, steel or light material, to guarantee accurate measurement of every product. Here, the distinctive feature lies in making the measurement: in fact, the test and measuring devices provide assessment, documentation and display. We can also build custom test devices to meet customer requirements”.
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Machine Tools
HIGH MILLING PERFORMANCE The most recent one is the high-speed, high-performance milling machine with 5 continuous interpolated axes, Flymill HD. It is ideal for machining superalloy, steel and aluminum parts with complex three-dimensional shapes that must be accurately made. To ensure high performance, the Flymill is equipped with sturdy shoulders made using the exclusive Metalquartz® technology, which provides high structural rigidity and a high degree of vibration damping to guarantee the best surface finishing and a longer tool life. The wide work table size, the strength of the structure and the large operating strokes make this high-speed milling machine suitable to be used in a single work area or in pendulum mode. The Breton Flymill is equipped with the Tornado HD head, fitted with a 75kW, 300 Nm, 14000 RPM spindle for rough machining and finishing. Also noteworthy is the compact structure that meets the increasingly widespread demand for small-footprint systems.
“State-of-the-art technology and many years of know-how”, explain Frank Elzener and Stefan Lühr, managing director and owner of the company respectively, “allow us to provide our customers with everything they need for each process phase, from design and manufacture to assembly and testing, giving them a single source procurement service”.
The second Breton machine installed in WFT is a Matrix 1000 with axis strokes of 2200 x 2500 x 1000 mm. Thanks to the speed of its linear axes, which can reach 60 m/ min, and its Direct Drive head with a continuous C-axis rotation speed of 100 rpm, the Matrix can perform uncommon highprecision and dynamic machining of complex profiles with 5 continuous axis.
The available spindles range allow the machine to easily handle high-speed machining and milling of both light alloys and other special alloys that are often used in the aerospace industry. The completely enclosed structure with mechanisms at the top of the machine offers great operator safety with the best machining reliability and precision. The accuracy performances are also achieved through the thermo-symmetry of the structure and the thermal stabilization system which keeps the temperature of all the moving parts aligned with that of the machine structure during operation. 7 all the ne ws on
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NEWS ➜
Bre t o n W O R K I N G C E N T E R
MATRIX 1000
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The name “Matrix 1000” is not new for Breton; originally intended for the mould&die market, it had excellent success over the years. The machine has been completely redesigned to cope with changes in the market, thus maintaining only the name and the target sector; it now includes many new features that are required in other sectors such as aeronautics, precisely for its stiffness, accuracy and working envelope. Some of the ideas that contributed to the success of the previous Matrix 1000 have withstood the test of time, while others have been reviewed and updated. In fact, although it was designed for mould&die makers, it has been particularly successful also in the aeronautical world. Some solutions designed for modularity have an impact on costs so, the machine concept has been redesigned, keeping the good points of the previous versions, simplifying where possible and ensuring the interchangeability of the accessories such as different choice of milling heads so that the machine can be better used in the aerospace sector. 8
Listen to the users Who better than the final user can say what a specific sector needs? Breton passed from a top-down approach, where it offers solutions and features to the market, to a bottom-up approach, where it is the market that guides the new model development. Therefore the new Matrix 1000 was born from the requests of the mould&die market. The approach is simple: the travels were based on the largest workpiece that is generally machined in the mould&die sector, such as car bumpers or dashboards. The design then started from the simplest things, that normally are considered unimportant but are required in all workshops (ergonomic access to the working area or easily cleanable working area from chips); then, it moves on to more complex aspects (greater structural rigidity for significant removal or reduced thermal expansion). This approach could be described as a true user experience. There is another direct request from users: “it must cost less and produce
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Machine Tools
M AT R I X 1 0 0 0 W O R K I N G C E N T E R
Breton
With renewed form and structure, Breton Matrix 1000 has been designed to meet the needs of mould&die makers thanks to some innovative solutions specific for the sector
By default, Matrix 1000 is offered with Heidenhain iTNC 640 numerical control, but it is also available with Siemens 840D SL. Redesigned from top to bottom An excellent job has been done in developing and engineering the machine; it costs less than the previous version, but at the same time it features better accuracy, performance and productivity. In fact, it has smaller footprint than the previous model, even though the axis travels are longer (300 mm more in the Y direction). Workshops often have problems with space, and sometimes this can be a key factor when choosing one model over another. Modularity is still significant : a fix size for the Z and Y axes and a choice of travels for the X axis, from 2500 mm to 4000 mm. Breton designers have provided a stainless steel cover for the internal working area ; this solution avoids the risk of “paint removal”. This is an added value really appreciated by machine users. Chip evacuation is another feature that users appreciate. Unlike steel machining, aluminum produces a considerable amount of chips: machining aluminium rotary moulds means starting from large blocks and removing up to 80/90% of the stock material. In this case, being able to rely on an efficient evacuation system implies keeping the
more” - difficult to achieve, but not impossible. In fact, Breton designers were able to achieve better performance at a lower price.
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Designed for the world of mould&die industry Among the new features that Breton has introduced into this version, there is the right angle head, particularly appreciated by mould&die makers. In fact, compared to a fork-type head, it can machine closer to the workpiece (therefore with shorter tools) or reach points that would otherwise be inaccessible by a forked head. Breton has given this head model distinctive features such as direct drive, safety brakes and encoders, as well as a case that resists bending and twisting as much as the forked one. Obviously, the right angle head is not an acceptable solution in the aeronautical sector, this is the reason why the forked head is still available. This is one of the features that makes Matrix 1000 suitable for such different application sectors.
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WORKING CENTER
working area clean and preventing accumulation that can create future problems to the machine. For this reason, Breton has provided a front belt conveyor, which allows the doors to be opened easily, and two lateral chip evacuation belts that take the remaining chips to the front conveyor. Moreover, the rear wall is up against the table to prevent material accumulation. The stainless steel walls also protect columns and bellows, which remain clean and easy to wash. Details that count Installation time is a detail that means a lot to end users. For this reason, Breton has introduced significant improvements that have reduced the commissioning time by approximately 20%. The base version has a step to access the working area; in this way, it can be installed directly on the floor or industrial foundations, without the need for any contractor work. The machine just needs to be anchored, and it is ready for operation. This will be useful also in case the machine has to be relocated in the future. There is no need for foundation work to allocate the conveyor; moreover, all the cables pass through the machine. For those who prefer a solution with the work table at floor level (e.g. to enter directly with a forklift), it is possible to dig a pit to recess the work table. The chip evacuation system is positioned behind the front doors, with 10
its way-out on the tool-store side (either right or left), while the operator can operate the numerical control panel on the front side. The tool-store and the chip box are accessible from the machine side, so there is no need to go to the back side. On one side, there is access for tool store expansion, with 30 positions in the base version, which can be doubled on request. These are values that are perfectly aligned with the needs of the mould&die making sector, where large numbers of tools are not required. Regarding usability, it is important to remember that the electrical cabinets need a safety distance from the other machines in order to be opened safely. In the new Matrix 1000 they are located at the rear, so that it can be installed 1 meter (40�) from the wall without running into operational and maintenance safety issues. Better chip removal An increase in removal capacity has been achieved by using a structure that has been designed and built to support higher cutting forces. Previously, the spindle could reach 100 Nm of torque, while the versions
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designed for this evolution can provide now a continuous torque of 160 Nm on a 18,000 rpm spindle. Alternatively, there are other spindle models with 100 Nm and 18,000 rpm or 64 Nm and 28,000 rpm. The columns, bridge and ram are structurally have increased the rigidity In addition to its stiffness (certified by FEM structural analysis), the new Matrix 1000 has a patented solution that makes it less sensitive to temperature variations. Together with a thermosymmetric structure, this means an increase of its overall accuracy in all operating conditions. Another requirement of the mould&die sector is more robust tool tapers, both to support the increased removal capacity of the machine and to improve the operating conditions of the tools (as they are subjected to less vibration). For this reason, Breton has provided both the traditional HSK63 taper and the HSK100 version. Matrix is a gantry type with 4 motors on the master/slave X axis and backlash recovery; the Y axis is moved by a recirculating ball screw, while the Z axis has two recirculating ball screws without balancing, which increases reactivity during machining. A ram with hydrostatic guides, a solution that dampens vibrations even more effectively, is available on request. The rotary axes use torque motors with encoders, while for the linear axes, Breton preferred to stick to a more “traditional” solution, which still ensures high performance levels; ballscrews and racks ensure up to 5 m/s2 and 50 m/min, without the problems associated with using linear motors (consumption, complex cooling system design, etc.).
Machine Tools
Thermal shield Breton deals with temperature variations in a special way; within obvious limits, the machine can be hot, and must remain so. The important thing is that this temperature variation is gradual and controlled, so that the thermo-symmetric structure can adapt. To achieve this result, the structure has special insulation; if there is a sudden change in outside temperature, e.g. of around 5 °C, the machine opposes this change and takes much longer to heat up and therefore expand. This idea is already well known in the construction industry, where thermal cladding is used to make buildings more efficient by keeping the temperatures as stable as possible compared to the outside. The temperature difference between the sheet metal panels that make up the machine is 0.2 °C, a very small values that can be managed by the passive (thermal cladding) and active (electronic) compensation systems in Matrix 1000. In addition to the temperature sensors placed in the main structure of the machine, there are also vibration sensors on the head already in the base version: when needed they stops machining to prevent any damage (such as is unexpected and excessive stock to be removed). As option an adaptive package is available on request, which varies the machining parameters according to the measured machine reactions (power consumption, vibrations, etc.). The spindle can be easily removed by undoing a few screws and using a quick cabling system. In this way, the user can change it quickly when needed (such as a collision or the requirement for different performance) and restart after a centering cycle. On request, Breton can also supply an automatic cartridge changing device.
. M AT R I X 1 0 0 0
Breton
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Enhancing your production process Engineering | Clamping | Motion | Control
Flexibility Setup time reduction High accuracy
Modular and standardized clamping systems for products and production equipments Scan to get full access to FCS products information
Visit us at
www.fcssystem.com
INTERNATIONAL PATENT
TNC 640 – High-End Control for Milling and Turning Operations The TNC 640 from HEIDENHAIN: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turning—within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action. This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the TNC 640.
HEIDENHAIN ITALIANA S.r.l.
20128 Milan, Italiy
Angle Encoders
Contouring Controls
Linear Encoders
Phone +39 02 27075-1 Position Displays
Length Gauges
www.heidenhain.it Rotary Encoders
AEROSPACE ➜
Bre t o n D E E P S P A C E I N V E S T I G A T I O N
BRETON FOR DEEP SPACE INVESTIGATION
Accuracy and reliability
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The responsible for the ELT project at SCHOTT, Thomas Werner, emphasize some of the key characteristics of our machine in a recent article on their website: “The machining is so precise that ZERODUR® mirror substrates with a surface shape tolerance of less than 100 micrometers, or 0.1 millimeters, can be ground in the future”. “The precision is thus twice as much than with the previous machine, which is at 0.2 millimeter envelope curve accuracy, the technical term used”.
A window into distant galaxies Astronomers are constantly looking for ways to obtain deeper insights of outer space so that they can further explore the universe. Technology such as the Extremely Large Telescope (ELT) must be able to capture as much light as possible before transferring it onto scientific instruments. To achieve this critical process, the size of the mirrors are constantly increasing and the designs for them are becoming more complex. SCHOTT’s ZERODUR® glass-ceramic ensures that crisp images are available to help unlock the mysteries of the cosmos. 14
04 Our Breton Flymill perfectly answers all the project advanced claims: the mirror material has no thermal dilatation so our machine must have an extreme stability, the mirror need to be machined with pure water so our equipment has special solutions in order to avoid corrosion, the table, for example, is covered with Breton LapitecÂŽ, a special ceramic material. Flymill is capable to turn a diameter up to 5 m with a surface tolerance of 0,02 mm respecting the customer request of 100% process stability.
D E E P S PA C E I N V E S T I G AT I O N
After a long and complex competition, Breton was selected to provide the machine that will create the more advanced mirrors for the biggest telescope ever seen. The machine provided to Schott is a Flymill 1300/2T K60 with axis strokes X=6000 Y=4500 Z=1300, 5 m turning table with special LapitecÂŽ surface, spindle up to 450 Nm, 14000 RPM, 85 kW, head change system.
Machine Tools
ESO: Extremely Large Telescope
Breton
Read the full article on Schott website:
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AEROSPACE ➜
Bre t o n P I A G G I O A E R O S P A C E
BRETON FOR LONG TIME RELATION FOR INNOVATION
Partner for accuracy
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It was 2010 when Luca Tagarelli, engineer and Manufacturing manager at Piaggio Aerospace, was describing the reasons why Piaggio Aerospace chose Breton as a partner for a new strategical job with one of the major helicopter engine companies. The project was for 5 Ultrix 800 RT with 5 pallets each and the first three were already machining in the Finale Ligure plant. The location was only one of question raised by the journalist as the company was lying in front of the sea surrounded by a beautiful tourist area. Now the situation is changed and Piaggio Aerospace has an amazing new plant in Villanova d’Albenga with direct access to the local airport. Of course they lost the sea view but they have built their future investing in an high technology structure, with a very rational machine layout. All their customers have been more than happy to touch the results achieved, giving them a very high confidence in their production stability.
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Machine Tools
P I A G G I O A E R O S PA C E
They have been so impressed that they decided to give Piaggio Aerospace more job and new customers have been acquired. Thanks to the demonstrated performances Breton have been a directly involved partner during the plant opening and has completed the last two Ultrix installation in a very compact and efficient layout that will allow one operator to run two machines keeping the complete process control of both. Now that the original project is completed Piaggio Aerospace is capable to demonstrate an incredible production efficiency thanks to the machine accuracy, measuring capability, high precision setup station and a turn key solution developed by Breton in strong cooperation with Piaggio Aerospace technicians in order to allow them to manage the process. In the aerospace production a turn key process developed and provided like a black-box is not a good solution. The production volumes are normally very low and with a casting or forging variation that request an adaptive production process. The final customer is also an important variability factor as he will quite often change drawings and product specification. Breton, while developing the turn key solution for Piaggio Aerospace, involved the final users on a weekly base and gave them a complete open production process, easy to be managed and adapted.
The good partnership and the demonstrated machine accuracy convinced Piaggio Aerospace to invest even more purchasing another Ultrix 800RT with 5 pallets and one Ultrix 1000RT. The Ultrix 800RT is fitted with a special angular head with a fast manual tool change, capable to allow the machining inside some very small titanium components for a major aero engine companies, supplier for the military last generation air supremacy aircraft. Ultrix 1000RT has been chosen to replace an old high precision Dixi machine used to produce production fixtures that was only capable to drill and ream high accuracy holes. The remaining part of the fixtures was produced on old NC milling centers and lathes. Breton solution gave them a single new machine capable to substitute all the others, easy to be programmed by the operator and with a perfect piece accessibility. 17 all the ne ws on
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NEWS ➜
B re t o n W O R K I N G C E N T E R
ULTRIX 1200 EVO
Doubled working area with 30% less footprint
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The latest machine born in Breton, natural evolution of Ultrix and Xceeder family doubles the working area and reduces the footprint of 30%. Breton thinks that this machine configuration is the best to machine aerospace engine components; the vertical spindle allow an easier piece setup, the trunnion table offers a better accessibility and can be used to remove chips rotating A axis. The machine has a great dynamic in order to guarantee high productivity also on 5 axis machining of aluminum components. The design is thermo-symmetric in order to reduce and better control structural deformations due to temperature effects. Of course all the heating sources are cooled to avoid heat transfer to other components.
The machine basement is produced using MetalquartzŽ, a Breton patent, resulting in a structure better than a cast iron one from both rigidity and vibration dumping point of view. All the machine components involved in operators preventive maintenance are grouped in an easily accessible area. The tool change has the loading area in front of the machine, different types of tool holders (Capto, Hsk, ‌) can be automatically managed on milling spindle, turning bar or angular head. One or two angular heads can be stored in the machine back area, loading and downloading is automatic and the assembly with the RAM is based on a hydraulic clamping allowing to transfer the full torque and power of the spindle. The tool change is automatic too.
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Machine Tools
U LT R I X 1 2 0 0 E V O
Breton
UP TO 600 Nm
H=1000
D=1400
2,5 2,5ton ton
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The CN can be adjusted in height and inclination in order to increase operators comfort. Piece accessibility has been improved allowing the operator to stay at only .6 in from the turning table. Machine roof can be completely opened to easily load fixtures and pieces. All the working area is covered with stainless steel creating a bright, easy to clean and antiage result. Chip wear will be just history! All the axis are pressurized avoiding contaminations. The new structure is capable to support also heavy machining operations thanks to the innovative 600 Nm spindle and hydrostatic RAM version that increases even more the vibration dumping results. Also the turning bar performances have been increased thanks to the new available length of 17.7 in. It can be fitted with Capto C8 or HSK-T 100. The A axis is driven by two powerful torque motors and can be clamped using a double high torque brake, one each side. A torque motor too, up to 450 RPM and 4500 Nm, drives the turning table. The new Ultrix 1200 EVO, and the milling version Xceeder 1400, are the biggest existing of this type; they give to the user a piece accessibility never seen in the Aerospace market, even in the internal or the external part of the component allowing a productivity with no compromises.
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Digitalization in Machine Tool Manufacturing Increased efficiency, enhanced flexibility and shorter time to market – all this is promised by digitalization. Whether integrated engineering in machine development or networking machine tools in a production landscape. We support machine builders as well as machine tool users with our solutions! The basis is always our SINUMERIKŽ CNC with its openness and technological bandwidth.
siemens.com/sinumerik
To prevent vibrations in machining difficultto-access features that require tools with long overhangs in milling, turning, and boring, Seco has engineered and patented the comprehensive range of Seco Steadyline toolholders.
STEADYLINE VIBRATION DAMPING TOOL-HOLDERS
WWW.SECOTOOLS.COM
TM
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Machine Tools
REFERENCES
Breton
B re t o n R E F E R E N C E S
WORKING WITH THE BEST
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06 ULTRIX
XCEEDER Metalquartz速
Xceeder NEW 1400
Thermostable
Metalquartz速
Thermostable
5-Axis high speed vertical machining center with trunnion table. High precision milling and grinding on super alloys, titanium, steel, aluminum and composite. Three machine size, machinable diameter up to 1600 mm.
5-Axis high speed vertical machining center with trunnion table. High precision turning, milling and grinding on super alloys, titanium, steel, aluminum and composite. Three machine size, machinable diameter up to 1600 mm.
MATRIX 800
MATRIX 1000-1300 Metalquartz速
Thermostable
Ultrix NEW 1200 EVO
Metalquartz速
Matrix NEW 1000
Thermostable
Thermal shield
5-Axis high speed vertical machining center for mould and aerospace components. High precision milling on steel, aluminum and composite. Spindle change, fork or orthogonal head. 24
5-Axis high speed vertical machining center for mould and aerospace components. High precision milling on steel, aluminum and composite. Small footprint.
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Machine Tools
PRODUCT RANGE
Breton
B re t o n W O R K I N G C E N T E R
PRODUCT RANGE MAXIMA Metalquartz®
FLYMILL Metalquartz®
HD version
Thermostable
Thermostable
6-Axis high speed vertical machining center for medium and big size parts. High precision turning, milling and grinding on super alloys, titanium, steel, aluminum and composite. Head change, pendular machining. Up to 5 m turning diameter.
EAGLE
5-Axis high speed vertical machining center for medium and wide components. High precision milling on super alloys, titanium, steel, aluminum and composite. Head change, pendular machining, modular design.
RAPTOR
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5-Axis high speed vertical machining center for milling, trimming, routing & drilling. Wide available range, Z stroke up to 2500 mm. Machining on aluminum and composite.
5-Axis high speed vertical machining center for milling, trimming, routing & drilling. The best ratio between rigidity and high dynamics on composite and resin. 25 all the ne ws on
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TECHNOLOGY ➜
B re t o n A U T O M A T I O N
AUTOMATION
Wide range of automation solutions for Breton machines
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No one seems to remember that the machine tool itself it’s an automation! Not too many years ago, the NC was the operator brain and robots were still to be invented. Now the situation is completely changed and in the industrialized area, in order to be competitive, we need to remove the constraint of a ration 1:1 between operator and machine. The automotive industry started with the massive production of few products, the high technology companies need to do the same with many small batches of complex and different products.
Breton production is dedicated to these customers, providing them solutions capable to run alone 24 hours/day with remote monitoring and control. The electronic and software improvements are a big help to reach this challenging target but they cannot work without a strong and reliable machine automation. The best way to describe automation solutions that Breton can provide is to show some real applications developed to answer real customer claims.
PALLET CHANGER WITH 5 STATIONS Customer request: remove any time spent for machine setup, avoid mistakes due to wrong fixture setup, disconnect operator setup time from machine operating time. Solution: Breton designed and supplied to Piaggio Aerospace 6 tailor made Ultrix 800 machining centers featuring special ergonomic solutions for the best workpiece accessibility, each one is equipped with a total of 5 pallets (4 loading stations and 1 high precision setup station) and a manipulator. The result is a multipallet solution characterized by a very compact layout. The extreme accuracy of Breton machine tools is possible also thanks to the special pallet changer solution, based on an hirth serration that provides higher performances respect to the standard competitors system. Pneumatic, hydraulic and electronic connections can be supply to the tooling.
MEASURING FEATURES Customer request: Reduce the features cost and complexity, be sure to remove from the machine a conforming piece. Solution: The machine probing systems are provided as standard solution by many different competitors. The difference of Breton solution is the strong integration with the machining process and the measuring performances thanks to high machine accuracy. Breton can provide a turn-key solution to check the machine condition before starting operation, perform a perfect piece setup, even on deformed components, machine, measure and automatically correct the part saving all the measurements for statistical analysis. The only thing that the operator has to do is press the start green button. The final result for an important Aerospace customer is a measuring difference between Breton Ultrix and CMM of less than 0,01 mm. 26
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Machine Tools
A U T O M AT I O N
Breton
HEADS CHANGER Customer request: strong reduction of cycle time while performing roughing and finishing operations on large size aerospace components. Solution: Breton supplied to an important Aerospace company a Breton Maxima 1600, fitted with a head changer system. The head storage hosts an high torque milling spindle (up to 480 Nm and 14,000 rpm) suitable for roughing, and a finishing spindle (up to 94 Nm and 28,000 rpm). The machine is equipped with two bridges and is 16 meters in length, so can be configured to run two pieces together (for example one roughing operation and one finishing operation) or a single long piece removing material with the two heads. Breton Flymill 1600 HD K160 fully achieved the customer requirements providing a strong cycle time reduction together with a perfect flexibility.
PENDULAR MODE WORKTABLE CHANGER Customer request: avoid long machine stop during the setup operation of a typical aircraft structure big component. Solution: this problem can be solved providing a long machine with two separated areas (one for machining and one for piece setup) or by using a table change system. For TAI (Turkish Aerospace Industries) Breton chose the second solution, providing a total of 3 Breton Flymill 1300 2T K30, equipped with a table change system that allow the operator to spend all the time he needs to perform a perfect piece setup while the machine is milling another component on the second table.
MULTI POSITION TOOL STORAGE Customer request: the use of multitasking machines has increased the number of requested tools (milling, turning, grinding) but not the available space. Customers want smart solutions. Solution: one Breton well known key feature is the development of tailor made solutions. We are capable to take the best-in-class tool storage solutions from the market and adapt to the different customer requirements. One example is the 200 positions tower type tool storage integrated on our Breton Maxima 1600 (mixing HSK-A100 for milling and Capto C8 for turning) with up to 3500 mm turning capability. Another solution is the 200 positions tool storage fitted on our Breton Maxima 2000 K80. Breton designer used the 8 meter machine length to hide the system in the machine footprint. A robot picks up the tool and transfers it to a tool changer avoiding any waiting time.
ROBOT Customer request: create an automatic flexible manufacturing system to produce tire moulds with a minimum operator surveillance. Solution: Breton supplied to an important automotive company three machines, 2 Xceeder 900 and 1 Ultrix 800, with pallet change
system served by a robot on rails collecting pieces and fixture from a big storage. Breton was responsible for the complete FMS solution and the final acceptance criteria were very severe but they have been achieved. The robot gives the system an higher flexibility respect to a classical FMS solution, in this way it will be possible to change easily the production in the future.
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TECHNOLOGY ➜
B re t o n
COUNTERSINK? NO PROBLEM
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The use of rivets is one of the most common standards for the permanent assembly of structural parts in aerospace and automotive sectors. Despite some minor limitations, this system offers useful advantages in the assembly process: rivets are cheap, the procedure is easy and fast, they are available in many different types covering any need, there is a long history and experience in their use leading to a good reliability guarantee, compared to other permanent fixations, they can be disassembled quite easily with specific tools, they allow a calculated residual flexibility of the assembly and they allow easy and fast repair even on the field. When rivets are used to assemble the external layers on the supporting structures, they need to fulfill another very important role because the resulting assembly is directly exposed to the airflow: the final surface must be as smooth as possible in order not to affect the 28
aerodynamic performances. This specific need is very common in the aeronautic and aerospace field and all designers solve it by selecting rivets with countersunk head. It becomes therefore evident the need of an accurate hole on the surface prepared with a countersink: the rivet head needs to be hidden below or in line with the external surface profile. Just to reinforce the importance of the final surface quality the rivet head flush requirement is directly expressed on the assembly drawing through specific symbols (like a welded joint) and described in detail through dedicated quality procedures involving, very often, also a source qualification need. The standard way of performing the rivet assembly is manual with specific tools that allow improving the reliability of the process. Generally, the structural parts and the sheet metal pieces are machined and prepared with smaller holes in order to guide the manual tools used to create the final hole and
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Machine Tools
The use of rivets in the aerospace world is fundamental but it requires hard manual work. Breton has devised a system that facilitates and improves the aircraft assembling.
COUNTERSINK? NO PROBLEM
Breton
countersink prior to assemble the rivet. Sometimes only one of the two elements to be assembled is pre-drilled in order to allow compensation of assembly misalignments; in this case, operator’s job become even more complex and sensitive, thus requiring higher manual skills. Until the business remains focused on small quantities and the market is ready to reward the “hand-made”, and the consequent high value added, as a “plus”, it’s possible to sustain the manual production process with respect to massive production competitors. How does all this match with NC 5 axis machining? When the scenario changes to big numbers (typical of the civil market) with reduced prices and margins, the only solution to stay competitive is the process standardization and automation, so the aerospace industry needs to find a partner who can help it achieving critical goals.
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On the market, it is possible to find solutions that substitute the operator job with a quite complex machine requesting to introduce the full assembly jig into the machine in order to drill and rivet the components replicating the operator’s gestures. This strategy is very expensive, requiring a huge space allocation and presenting many times issues due to aircraft structures accessibility limitations. Breton is following a different way, allowing to save the huge amount of money necessary for the previous type of investment and keeping the maximum flexibility to apply the solution to any type of component. Breton has developed specific machines and several solutions to support this type of challenge and has also a very strong and experienced process development team available to support customers before and after the integration of a fully comprehensive solution. The only ground condition is the availability of a 3D part model, Breton takes care of anything else. For each of the previous points supporting the benefits of a manual riveting process, Breton has a specific automatic solution leaving the final fastening to the operator but with the hole and countersink already prepared in the correct position, shape and depth: • Position precision is not an issue for any Breton equipment that is designed to achieve the best 5-axis tolerance on the market. • A specific automatic probing head is capable to calculate the real sur face position in respect to that of the 3D model and calculate the corrections in order to recover depth of cut and surface perpendicularity • The machine position is automatically modified without any operator assistance before drilling the hole and countersink • With this solution the fixture only needs to keep the piece well fixed but it can leave to the machine probing capability the real shape calculation • The composite dust issue is solved avoiding the operator to be
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10 exposed to it during the material cutting • The composite integrity is guaranteed using a special developed solution that avoids any contamination and completely removes any dust • All the cutting parameters can be controlled much better than in a manual mode • The software is also capable to monitor the surface stability during the cutting operation and can be programmed to react in different ways according to the material responsiveness • The structural part can be machined on the same trimming machine in order to have the same level of precision. This way is the first step to guarantee a good assembly performance.
The core of Breton automatic countersink solution is the special probing head and compensating software. They have both been designed at Breton’s and patented due to their specific and unique capabilities on the market. The special probing head is stored in a specific holding device on the machine, protected and located outside the working area; when necessary, the machine automatically picks it up, while keeping the tool change capability monitored through a specific application in order to avoid any collision with the device. The system is composed of three mechanical transducers managed by a specifically developed nc control application in order to acquire the true position and orientation of the piece surface around the hole to be done. The drilling program is a standard one where the machining cycle is substituted with the Breton routine to activate the countersinking head. The typical drilling process follows these steps:
COUNTERSINK? NO PROBLEM
• the machine collects the special probing device • the machine picks up and measures the cutting tool (using a specific breton routine) • the machine sets up the probing device on a reference gauge integrated in the machine (using a specific breton routine) • the machine probes the surface in the theoretical position and orientation • the real position and orientation is recalculated by Breton software • depending on the surface type and scratch sensibility, the machine position and orientation are corrected by either keeping the probes in contact with the piece or retracting the machine from it (average time of the full probing and position adjustment is 6 seconds) • the drilling and countersinking cutter proceeds along the real hole axis until the probes detect the correct depth of cut (this time depends on the type of material, layer depth, type of cutter, etc.). The system is capable to respect a depth tolerance of +- 0.03 mm on a stable surface (or +- 0.06 mm if the surface is not perfectly supported and fixed by the fixture). The machine head is also equipped with a special dust extraction hood in order to collect all the dust generated by the drilling process. There is no limitation in spindle performances as all the probing systems are static and connected to the head flange without any external wire. Depending on the material type, the head can supply compressed air, spray oil mist or pressurized coolant up to 40 bar as the probing devices are fully sealed. The system can be installed on any breton machine giving the customer huge advantages compared to the manual process, spending just a small portion of the investment requested by more sophisticated solutions. (breton is not yet assembling the rivets…). Since one of Breton’s major points of strength is its capability to listen to the customer’s requirements, we are working to further improve this system reviewing the design and testing a contactless solution. 30
Machine Tools
SPRINT™ system High-speed on-machine contact scanning system for exceptionally fast workpiece set-up and in-process control
Workpiece set-up: • Fastest available set-up routines for a contact probe • Accurate workpiece set-up even with measurement at rapid (G0) feedrates • Programed through G-code macros
In-process control: • True 3D measurement for in-process control and inspection • High-speed measurement of 3D curved surfaces • Specialist data processing for fully integrated adaptive processes
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For more information visit www.renishaw.com/sprint
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Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire GL12 8JR. United Kingdom. T +44 (0) 1453 524111 F +44 (0) 1453 524201 E uk@renishaw.com
www.renishaw.com
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TECHNOLOGY ➜
Bre t o n
BRETON ULTRASONIC KNIFE AND ROTARY DISK
Stop dust issues, perfect honeycombs
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Honeycomb structures are widely used in many high technology applications thanks to their unique properties. Like any composite material it can be designed exactly to achieve the project requirements. The designer can chose the base material and the resin composition in order to create the best compromise between weight and physical and mechanical properties. The cell shape and dimension are then the secret that allow to achieve an incredible ratio between weight and strenght! Closing the upper and lower side of the honeycomb with a metal or carbon layer, the resulting structure is incredibly stronger than the same weight metallic component.
Of course what is perfect for the designer is generally not the same for the machining. Also honeycomb structures follow this rule presenting many interesting challenges for the cutters and the machines. Basically we can use two different approach to cut these structure. The first one is to machine the core and the upper and lower layers separately. The second one is to cut the final structure assembled. Both techniques present advantages and disadvantages so the best one depends by component shape and materials combination. In any case the cutter has to move through different material properties and behaviours along the cutting path. In order to guarantee the best final structural performance the cut must be clean, free from delamination, chips or dust. 32
Breton
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Machine Tools
The ultrasonic cutting technology is a very good solution when the core material is Aramidic one (paper with resin). The combination between a very sharp cutting edge and the ultrasonic vibration creates a fast and clean cut avoiding any cell damage and providing a component ready for the following assembly processing. Breton has developed a complete automatic solution for both ultrasonic knifes and ultrasonic rotary disk that can be fitted on any machine. The cutting process is completely managed by the NC program and the ultrasonic heads are stored in a dedicated tool change, o the operator can use this technology as any other standard cutting tool. Breton can provide ultrasonic knifes up to a lenght of 125 mm and ultrasonic rotary disks up to a diameter of 63 mm.
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weld
cut
punch
FLY
Helping customers worldwide turn
broach polish Mill
rivet
Inject
MEASURE
clamp
eject TUFT
Melt
TEST
grind
bend press
roll
www.korta.com
Romani Components
Linear ball guides
Ground ball screws
Hydrostatik elements
Linear units
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Power Transmission
Linear Motion
offers ideal solutions for Linear Motion and Power Transmission dedicated to marble and stone machineries.
Precision racks and pinions
Planetary precision reducers Via De Gasperi 146 | 20017 Rho (MI) | Italy Tel. +39 02.93906069 | Fax +39 02.87152704 info@romanicomponents.it
Machine Tools
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NEWS ➜
Bre t o n I N D U S T R Y 4.0
BRETON FOR INDUSTRY 4.0
Connect to the Industrial Revolution
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The AGE of connection is gone, now you must be interconnected! You can call it Industry 4.0, smart factory or anything else but it’s a real revolution! The IV industrial revolution comes after steam invention, electric power and computers. If correctly managed it’s a great opportunity for the industry. Working will be easier and safer for the operators, the machines will cooperate between each other, giving more time to concentrate on innovation and competitiveness.
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Machine Tools
INDUSTRY 4.0
Breton
Breton can offer a complete software suite to let you and your company jump into the new era! Breton Naviman and Breton Sentinel have been developed not only to interconnect our machines but all your shopfloor!
For further information
Another good news is that you can start with a very basic configuration to monitor the machines and than integrate the system step by step with additional apps.
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B re t o n
SALES & SERVICE
Great experience at your service
To be our customer means to choose quality, efficiency and excellence not only of machines and plants but also of complementary services. We provide our customers with a qualified pre-sale advice, an efficient installation and start-up service and a thorough training to operators in order to optimize the machine running. An excellent after-sale service composed of more than 50 technicians in charge with the installation and assistance at your site and a staff of in-house technicians for the "on-line" solution of the problems completes the package offered. A global presence with the maximum proximity to our customers enables us to respond to your requests from all over the world very quickly. A network of external authorized workshops located through out the world allows us to expedite your requests for spare parts and assistance in a more timely and widespread manner. NC Machine Tools machinetool.service@breton.it
Sales Service Sales & Service
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For further information
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Machine Tools
SALES & SERVICE
Breton
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.de
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B re t o n S E R V I C E
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Machine Tools
SERVICE
Breton
BRETON & TECMILL
Now even closer to our valued portuguese customers Great experience at your service
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Reliability is a must in every highly-competitive market and so in most of the applications where Breton machines are utilized. Customers are always looking for the highest up-time in order to increase their production efficiency and this is the reason why Breton machines are specifically designed to meet the highest availability rates without compromising dynamic and precision performances. However, something unexpected can always happen and that’s when efficiency means also to provide quick answers, fast problem solving to get the machine back in production « in a blink of an eye». In the global mold-making industry, the Portuguese one is among the most important players and, for sure, extremely demanding in terms of efficiency with machines working almost 24/7 all year long.
In September 2005, TecMill was certified NP EN ISO 9001 by SGS for Commercialization of machines and Technical service for machines. In February 2014 TecMill was awarded the NP 4492 certification for “Maintenance and technical service of equipment related to moulds, dies and cutting tools, tools and metalworking in general”. Beside being a well-known and reputed reference point for the national Moldmaker associations , TecMill is a key member of A.P.M.I. - Portuguese Association of Industrial Maintenance. With TecMill, customers can rely on 22 employees in the administration office, sales department and technical department. Installation and service are provided by 12 engineers with strong skills on mechanics, electronics, hydraulics, pneumatics and software. The field staff is equipped with state-of-the art tools and technologies (Laser, Ball Bar, PWM, Digital inclinometer, etc ). During 2016 and 2017, Breton with TecMill invested more than 700 working hours in training the Portuguese service team on the insights and peculiarities of Breton high-performance 5 axis machines. The free teleservice support included as a standard in every Breton machine and the availability of a quality local service are creating the perfect combination to make Breton customer confident and certain that, no matter what happens, their investment will get the best and quickest return.
In fact, figures indicate that Breton Machining Centers installed in Portugal are registering record tool contact times with high dynamics. Clearly, a key market that is for Breton of the essence today as it will be in the future. Determined to increase its presence and to get even closer to end-users, after extensive tests and evaluations, Breton signed an important agreement with one of the most serious and skilled Portuguese service providers: TecMill.
PORTUGAL, Rua D. Maria I, 56 | Casal do Relvas | 2440-354 Batalha T +351 244 766 155 / 244 766 099 | F +351 244 766 520 E-mail tecmill@tecmill.pt
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TecMill – Compra e Venda de Máquinas e Ferramentas, was founded in 2001 , having as main purpose the technical service and sales of equipment and tools for the mold industry. Since its creation, TecMill’s main objective has been to provide a quality service to its clients and help them finding the most cost-efficient and proven solutions.
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➜
Bre t o n
BRETON ENERGY SAVING Green power We are committed to reduce CO2 emissions using green energy from renewable sorces. Our offices in Castello di Godego, Vedelago and Campiglia dei Berici have 9000 solar panels for almost 160.000 sq.f. coverage.
Vedelago
Castello di Godego
All groups (e.g. cooling systems) automatically enter the stand-by mode by adjustable settings. Their restart before the next operation can be easily programmed. STA STO RT P
All BRETON machines recover kinetic energy from axes and spindle motors when decelerating, thanks to the Energy Recovery System. ERS avoids the need of dissipative systems.
10% up to
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ERS Energy Recovery System
3S Smart Start & Stop System
Breton
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Machine Tools
ISO 9001 Quality Management System certified ISO 14001 Environmental Management System certified
Motors Energy Class ≼ IE2
All motors go beyond the most severe regulations, with energy class equal to or better than IE2. Breton machines can also be equipped with IE3 or IE4 motors on request.
Friction reduction and Balancing System
Top class linear guides and RAM balancing system increase the machine efficiency and precision, reducing at the same time the energy consumption.
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Baying systems TS 8 ◾ Efficiency Modular accessories, fast assembly, time-saving planning ◾ Flexibility Up to 15% more installation space, available off the shelf, baying systems, cable entry
◾ Safety Automatic potential equalisation, certifications, climate control, IEC, 62208, UL, EMC ◾ Quality Surface treatment to automotive industry standards, large-scale production, R&D, high load capacity
Blue e+ The world’s most efficient range of cooling units ◾ Safe Longer service life of all components inside the enclosure and the cooling unit due to component-friendly cooling ◾ Efficient Energy savings of up to 75% due to speed-regulated components and heat pipe technology
◾ User-friendly Touch display and intelligent interfaces support intuitive operation ◾ Versatile Unique multi-voltage capability supports global use
www.rittal.it
Touch Probe TC60 Multidirectional Radio Transmission Wear-Free Contour Measurement Single & Mass Production
Fast. Precise. Economic. High Performance. Blum.
Blum-Novotest Srl | Italy | Tel. +39 031 283 955 | info@blum-novotest.it | Production Metrology Made in Germany | www.blum-novotest.com
Movement through innovation. For forty years now the name SCHLEIFRING has been a byword for top precision and reliability when transmitting data, energy and media between continuously rotating and stationary components in almost all high-tech industries around the world. Our solutions set new benchmarks and open up new engineering horizons for our customers. SCHLEIFRING has been developing and manufacturing products for the machine tool market for metals, stone and wood. Especially gold-wire technology proved itself to be an effective means of contacting transmission at an early stage and is thus still in use today. The products of SCHLEIFRING have proven themselves to be indispensable, particularly for highly complex and sophisticated machines, as they have always stayed abreast of the latest machine-tool developments with regard to data transmission and sensors. A very good example of this is the contactless transmission of data at up to 10 Gbit/s. SCHLEIFRING meets the challenges posed on machine tools by demanding ambient conditions, such as those caused by stone dust, coolants or vibrations, early on during the design and development phase and can thus react to individual requirements and demands. Every design is engineered and manufactured speciďŹ cally for the application in question. Thus, SCHLEIFRING also confronts future technical challenges with new technological solutions, for example contactless data-transmission connectors (GigaPlug), and thus makes many complex applications in the mechanical engineering industry possible.
Schleifring und Apparatebau GmbH Am Hardtanger 10 82256 FĂźrstenfeldbruck www.schleifring.de
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Bre t o n
ABOUT US
Across the years today and tomorrow
1963
FROM STONE
Revolutionary machines to process the natural stone Breton was first established in 1963 by Marcello Toncelli, who perceived the enormous potential in developing a market which was absolutely innovative and at the time practically unexplored: developing new technologies and manufacturing industrial plants for producing engineered stone. The founder’s farsighted entrepreneurship and his enormous aptitude for developing innovative ideas were the assets that enabled the company to rapidly grow becoming in just a few years an industrial reality in the foreground, and later to become the world market leader.
Since the beginning of its activity Breton has also dedicated itself to manufacturing machines and plants for processing natural stone. In the nineties, Breton forced its way in the field of high speed numerical control machining centres, becoming one of the world most important manufacturers in few years. 46
Breton’s machining centers stand out thanks to their top technological level, superior production performances, groundbreaking solutions and top quality of the product/service system offered. Breton holds the exclusive right on the “Metalquartz” technology applied to the sector of high speed machining centers, which allows to considerably increase the machining performances. Over the time, Breton developed a full range of machining centres, which satisfy all the requirements of the following industrial sectors: Aerospace, Defence, Aeronautics, Automotive, Naval, Motor Racing, Gears, Energy, Die, Automotive and Naval Modelling and Prototyping, General Manufacturing Industry. Breton S.p.A. is under the control of Luca and Dario Toncelli, which run the company with the collaboration of the founder’s long-time partner, Roberto Chiavacci, who holds the office of Vice President of the Board of Directors.
Breton
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Machine Tools
TO METAL
Revolutionary high speed milling and turning solutions The company occupies a land area of approx. 81.000 m², of which 40.000 are covered, and employs about 750 persons. Breton has been awarded the ISO 9001 Quality Certification and the ISO 14001 Certification.
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printed in italy by Laboratorio Grafico BST - 09/17 - EN
BRETON SPA VIA GARIBALDI, 27 31030 CASTELLO DI GODEGO TV - ITALY TEL +39 0423 7691 - FAX +39 0423 769600 info@breton.it - www.breton.it
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