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Wednesday, 7 December 2016

“We've shifted gear”

The arrival of a Breton Eagle in SCA's workshop in Gessate (Milan) not only solved a host of operational problems, it also allowed the company to approach sectors and materials that were hitherto excluded.
(From: Meccanica&Automazione)


SCA
Founded almost fifty years ago as specialised manufacturer of foundry moulds, SCA is currently headed by the third generation of the proprietor family and, in a sense, it's experiencing the third “revolution” or – more accurately – conscious evolution of its operating activities.
The company was incorporated in 1970 by Domenico Scalzo and is currently headed by his grandson assisted by the second generation of the family.
The Breton Eagle of SCA 
Like many companies set up in the 1970s, the business started in cramped premises and worked with all kinds of industrial sectors: from moulds for motorcycle cylinder heads and interior light fixtures, to the initial production of parts for the Italian bottling industry.

In fact, it was a customer in the bottling sector that provided the basis for SCA's first turning point. With the customer in question, which remains a point of reference for SCA, the company began a journey into the world of industrial automation that enabled it to build its technological expertise until becoming a qualified supplier of parts for bottling plants (glass and plastic).





Rather than resting on its laurels and running the risk of supplying a single customer, over the years SCA maintained or developed a series of opportunities in several sectors that differed widely from the automatic machinery field, until it gradually left its origins in foundry mould-making in the past.


Competing in multiple sectors
This direction change led SCA to work with numerous industrial sectors, especially those calling for the ability to work with different materials with high levels of precision and the maximum operational flexibility.

From food and chemicals to pharmaceuticals and cosmetics, the marine and aeronautical industry, and also construction of large size components for theatrical stage sets. These various different areas of activity called for the ability to work with a large range of different materials, which is why SCA's machining shop today is equipped with machines for plastics, metals, and even, marginally, woodworking machines. The diverse range of applications calls for specific machines for each material type, each capable of producing optimal results.


Alessio Restelli explains “Several years ago we decided to focus our investments on machine tools for metals and alloys. That's why we decided to purchase a large size machining centre for specific work processes on workpieces in aluminium and lightweight alloys. Unfortunately however, we soon discovered that the machine we had identified was unable to cope with the work in our production programme. We were looking for a machining centre with large working dimensions, capable of processing different materials and providing absolute reliability. Above all, we were seeking a definitive solution to the problems we had encountered. And the need was all the more pressing because we were very keen to enter new business sectors and consolidate our capital equipment”.



SCA found the answer by embarking on a series of analyses and checks, trawling through the information available on the various companies and products on the market.
“We soon realised that our requirements in terms of equipment and solutions were a very good fit with the machine tools produced by Breton which, thanks to its long experience in building machines for a range of materials from stone to metal, was the ideal candidate to provide the tranquillity we were looking for. This saw the start of a period of negotiation that went extremely smoothly, especially when we went to visit Breton at the company's headquarters, near Treviso".
Breton Eagle




A paradigm of rationality and organisational efficiency.”
The final choice fell on the Eagle, a gantry-type machining centre offering exceptionally generous working dimensions: 4200 mm (X) x 3000 mm (Y) axis x 1500 mm (Z). We then requested that these characteristics be integrated with a separate lath so we could turn workpieces of up to two metres in length, using the Eagle head (shown in the attached photos) as a turning-milling device.



Restelli explains – “Our Eagle is not merely an extremely efficient machine able to produce work of the utmost quality and with exceptional dimensional precision, it also allowed us to benefit from the positive experience of working with the Breton team that were looking after our interests. Apart from absolute respect of precision and times, we were also impressed by the creation of a valuable collaborative relationship that was built on our combined efforts to find the best possible solution to our needs".


"For sure, the machine tool in question is extremely valuable, but the whole process was also accompanied by a truly exceptional the level of customer care and assistance. We quickly realised that the people at Breton were far more than expert engineers. In some cases the relationships we developed morphed beyond the professional realm and became more akin to actual friendship.

We started to perceive Breton's people as an integral part of our own team - a development that brought substantial value to the whole process. For companies working in our sector it's extremely important to be able to rely on a partner that allows us to focus on our core business, without having to lose sleep about possible breakdowns, problems, or the inability to achieve the quality levels we need. Setting aside the problems and focusing on the job means that we can relax and get on with what we do best. And that's just as important to us as the very air we breathe”.



Breton Eagle, range for resins, composites and alloys


Eagle is fully articulated range of travelling bridge gantry machining centres dedicated to the world of composite materials, resins and aluminium. These machining centres are perfect for fast, high precision 5-axis machining of 5 faces of the workpiece with a single set-up operation.


The various configurations of EAGLE machining centres for composite materials make it possible to perform even the most complex tasks with the maximum flexibility and operating efficiency, with working dimensions from 2,000x2,500x1,000 mm up to 10,500x5,000x2,500 mm and beyond.



The machine offers the maximum production flexibility thanks to the possibility of configuring the work area, which can be optimized for machining single parts or pendulum machining operations. Our job is further facilitated by the optimal visibility of the work area and the double front and rear access doors, allowing easy loading and unloading procedures, tooling set-up and monitoring of machining operations.

Would you like to find out more about the Breton Eagle? For INFO and inquiries write to mail@breton.it.

Thursday, 3 November 2016

The 5-axis machining centre of the month: Breton Eagle



High-speed and developed to meet the needs of workshops that deal with materials such as resins, composites, aluminium and carbon, while guaranteeing dimensional accuracy. (From: Tecnologie Meccaniche)

Breton Eagle
In its history as a manufacturer of machine tools, Breton has always stood out for its care and quality in designing and manufacturing solutions for removing metal chips.

High accuracy combined with powers and torques capable of processing new materials have always been the strong points of the company from Castello di Godego (TV), to meet the needs of sectors such as aerospace, automotive and pattern making.
Breton Matrix 1000 Dynamic

For the best results, it has designed models like the Matrix machining centres, also used to process the lighter materials (aluminium, resins and composites), which still require fairly high accuracy and a good degree of chip removal.


However, Matrix is a model that, in some cases, could be overspecified for the real needs of these sectors in terms of power and accuracy and, as we know, users tend to prefer solutions that match their needs perfectly.
Often the market offers lower-performance solutions with inadequate volumetric accuracies. Eagle is Breton’s solution to meet these expectations.


A new application sector
Breton Eagle, the 5-axis machining centre of the month

Breton decided to create a product that is not in direct competition with other manufacturers, nor of course with any of the machines that it was already manufacturing, but to enter a niche that requires good accuracy without the need for large investments.

Not all customers can afford (or need) a high-power machine nor an extremely accurate one. This requirement is typical of those making aluminium moulds or carbon, composite or resin patterns and it became increasingly evident that there was a need to offer a product that could meet this demand. None of these applications requires very high accuracy, but they do need a higher accuracy than can be obtained with low-end machines.

Therefore, Eagle is a high-speed, 5-axis machining centre for milling, drilling and trimming medium and large components made of composites, sandwich structures, light alloys, resins and plastics, all with good dimensional accuracy.




This machine is conceptually simpler and more economical than a Matrix, but at the same time, it is able to guarantee an accuracy that is higher than anything available in the lightweight material machining sector.


Eagle is based on the manufacturing philosophy that has always distinguished Breton’s machines: vertical spindle, high-quality recirculating ball screws, axes drives with backlash recovery to ensure the desired accuracy, thermo-symmetric elements, symmetrical fork head and high-performance cooled motor spindles.


From an economic point of view, Eagle requires a much lower investment than buying a Matrix (about 30% less, depending on the configuration). This is a significant amount for a single machine, but often users need several machining centres dedicated to these tasks, so the economic benefit is even more apparent.


Modular construction






Eagle brings the construction philosophy of other Breton models: in fact, it is a gantry machine with high columns, balanced vertical axis and heads with a symmetrical structure so that thermal dilatation is always limited.

Not all workshops are equipped with air conditioning systems, and thermo-symmetric design reduces structural deformation and makes it easy to correct via software. Naturally, the points where heat is generated (like the head, A-axis and motor spindle) are cooled by a dedicated chiller to reduce heat transfer to other parts of the structure.

Like most of the machines manufactured by Breton, Eagle is also a highly modular design.
It is made entirely of electrowelded steel and is dimensioned using finite element analysis to reduce vibration and limit twisting. This choice allows it to meet the machine users’ need for modular dimensions, allowing Breton to customise the standard product easily to satisfy market demands.


The machine is driven by brushless motors. The bridge on which the gantry moves has racks with two motors and pinions with backlash recovery, which offers a stroke of 2 m and higher thanks to the modularity of the rack solution. Depending on the choice of model, in the Y-axis, the stroke starts from 2.5 m and can reach up to 5 m. Finally, the Z-axis stroke is 1 m for the most compact model and reaches 2.5 m for the largest one.




The streamlined structure can also reach considerable speeds and accelerations: 70 m/min on the X- and Y-axes, 50 m/min on the Z-axis (all the linear axes are equipped with encoders) with accelerations of up to 4 m/s2, 12 rpm on the A-axis and 19 on the C-axis.

The motor spindles are partly inherited from the Matrix, while others have been specially developed to meet the specific needs of users of this type of machine. Breton’s entry-level model offers a torque of 52 Nm, 16,000 rpm, 25 kW of power and is lubricated with grease. This choice was dictated by the typical field of application, namely aerospace, where lubricant leaks onto the composite or carbon parts are strictly forbidden.

Alternatively, there are other spindles developed in co-design with Breton's partners, which offer up to 40 kW and air/oil lubrication.

The machining head was developed to ensure the accuracy and performance required by this type of application sector: a solution that is compact, mechanically driven to achieve the desired performance without using the more expensive direct drive. It also has smaller pivots for improved penetration inside the workpiece, allowing it to perform all the required operations.


It is made from a cast iron block, a solution that effectively damps vibrations directly at the source. Equipped with brakes to work in 3+2 mode with locked axes, it ensures maximum rigidity even with challenging material removal.

The machine received a positive reaction from the pattern makers who make rotational moulds, which typically require heavy aluminium removal. The same goes for pattern makers who make scale Ureol parts, resin products and other prototype components.

Power and control

A requirement related to machining composite materials is that sometimes the structure contains threaded inserts to be drilled or small titanium strips.

Other solutions on the market are not able to cope with this kind of machining, which must therefore be carried out manually by an operator, with the problems of accuracy and productivity that this entails.

On the other hand, Eagle can even handle those workpieces that contain composites, aluminium and various inserts, completing the task directly in the machine.In the civil aerospace sector, Eagle is ideal for all the structural aluminium machining, interior structures, honeycomb panels, aramid fibres, aluminium and composites that required drilling and countersinking.

Obviously, Eagle is also able to machine harder materials, taking into account that its performance will be lower than that of, for example, a Matrix. The choice, therefore, will be dictated by the predominant type of machining to be performed and the materials to be used.


The accessories
Ultrasonic cutting head

In addition to the more traditional optionals, such as video cameras to monitor the machining area and tool magazines of various sizes, Breton has come up with a series of accessories dedicated to the specific application fields for which Eagle is intended.


An ultrasonic cutting head has been developed to prevent tearing or chipping the workpiece when machining composites. It can be managed like a common tool (in fact, it is housed in the magazine).

Also for composites and carbon parts, there is a countersinking control head. This is controlled automatically through simple templates in the numerical control and allows the effective hole position to be verified before countersinking. This procedure is essential, for example, with carbon aircraft doors because the carbon mould geometry is rarely exactly the same as the CAD model.
So, the system carries out a check to establish the effective hole position on the workpiece (using mechanical or laser sensing) at three points to determine its exact coordinates before counterboring. With respect to a sensing cycle, the times, and therefore the costs, are reduced significantly.



The numerical controls that can be installed on the Eagle are the Siemens 840D sl and Heidenhain 640 iTNC, both with full software options. Moreover, at the customer’s request, it is possible to develop applications, cycles and specific interfaces that run on the numerical control to improve machine utilisation.


Finally, there is an accessory with a 6th horizontal positioning axis, to perform turning that requires special workpiece positioning and complete accessibility in any situation.


Safe and productive

Depending on the specific use, the user can choose whether to machine dry or using cooling lubricants, as the machine can do both. Breton has provided for the use of evacuator belts, extraction systems or both. Where there are laminated materials, for which it is necessary to mill the carbon and then thread the aluminium inserts, the carbon dust can be handled by the extraction system and the aluminium chips by the evacuator belts.

Breton puts considerable effort into satisfying the Atex standard. When it comes to safety, especially in industrial systems, nobody wants to run into problems or “surprises”.
The machine is therefore fully closed, with top bellows to avoid dust dispersion within the workplace. There are also extraction systems on the table and spindle nose.

When machining graphite, whose dust is extremely aggressive to both mechanical and electrical parts, Breton offers IP65 cabinets for the electrical panels or, alternatively, located at an appropriate distance from the point where the dust is created.



Would you like to find out more about the Breton Eagle? For INFO and inquiries about this 5-axis machining centre write to mail@breton.it.

Monday, 26 September 2016

World premiere Breton at Bi-Mu: Ultrix 1200 EVO

Breton sets again the new technological edge in the vertical machining centres with its new 5-axis rotary-tilting machine, the biggest in the market.



Making its first world public appearance at the Bimu 2016 (Milan, Italy), the Breton Ultrix 1200 EVO is an high-end technological five interpolated axes multitasking machining centre, designed to achieve the highest performance in heavy milling and turning of tough materials such as special alloys, and titanium.


It guarantees high working flexibility, power, big working envelope, reduce footprint and the dynamics of a compact machine. 

Breton Ultrix 1200 Evo





Ultrix 1200 EVO is made for machining 3D shapes that require milling, drilling, turning and grinding. Operations that make it a suitable product for many sectors: from the aerospace industry to mould production and energy.

The advantage of this machine is that it can make complete parts, reducing the need for different configurations and positioning to a minimum, thereby ensuring quality and accuracy that is well above average.

The machine’s notably solid structure has a base onto which the gantry movement guides are fixed, while the automatic magazine is in a specially designed cavity on the left column.



Following Breton’s tradition, the material used for the structure of Ultrix 1200 is Metalquartz®, a polymeric resin that fills the machine structure to reach impressive rigidity and unequalled vibration damping capacity. 


These characteristics then grant high machining quality, top finishing levels and a longer tool life.

The GANTRY is made of electrowelded normalised steel and moves along the top of the two columns thanks to high-precision roller guides.

Two digital brushless AC motors drive its movement. Linear optical encoders with micrometric resolution, positioned on both sides, detect the bridge’s position.

The RAM is anchored to the front of the bridge and is also made of normalised steel. The RAM runs on the bridge, driven by a system of ball bearings and a preloaded double lead screw nut.

All powered by a brushless motor. Also in this case, the accuracy is ensured by Heidenhain optical encoders with micrometric resolution.

At the bottom of the RAM, near the motor spindle, there is a three-axis accelerometer sensor, which is very useful for monitoring the tool balancing during machining. 

This highly accurate system, with its software suite to establish the monitoring and intervention thresholds, reduces damage due to accidental collision, even during manual operations.

The TURNING TABLE tilts from -120° to +120°, and is driven by a direct drive motor.







It is hardly necessary to mention that each unit and bearing is kept at a completely stable temperature by a dedicated chiller and is controlled by high-resolution direct encoders.

Key points of the Ultrix 1200 EVO:



  Travels: 1700x1600x1000 mm

• Easy operator access to the work table thanks to wide front door openings.

• Dedicated turning tool
.




• Accessory management (additional heads, special tools, turning heads with transmission etc.) in the machine’s dedicated internal magazine, with automatic tool change.





• Tilting table available with dual Direct Drive or Dual Drive A axis with play recovery and max torques of up to 9000Nm.

• 
Milling/turning table with torques of 2000 to 5000Nm, max speed 450rpm.

• Heavy Duty HD version available with milling motor spindle with torques of up to 900 Nm and maximum speed of 14000rpm. 
Thanks to its high rotation speed, this solution allows significant roughing and excellent finishing of the workpieces, without changing machining centre.

• 
Symmetrical structures to reduce the impact of thermal expansion to a minimum.

• Base filled with Metalquartz® Breton ensures vibration damping and thermal stability.


For more info about NEW vertical machining center  Breton Ultrix 1200 EVO write at mail@breton.it.

We'll get back to you promptly.
Well, that’s all for today. 

Bye-bye
Sergio Prior

Thursday, 8 September 2016

Innovation and quality for aerospace applications by Breton

Aerospace, the industry continuously searching for innovative materials offering better performance and always looking for micrometrical accuracies.
Piaggio Aero Avanti Evo

An  industry that needs someone who can promptly develop cutting edge production solutions which could be both competitive and immediately reliable.

That's why many major Aerospace players selected Breton as a partner, the Italian company manufacturing high-speed machining centres: continuous research and innovation are in its DNA.

From the most affordable machine configurations up to the large and complex automated manufacturing systems, Breton is always focused in providing its customers with the best ‘Return Of Investment’ solutions.

http://bit.ly/1KsYKfH
Click on the image for a virtual tour inside Breton


At their engineering and manufacturing headquarter in Northern Italy as well as in the other 6 service centers worldwide, a dedicated staff of experts is performing preventive part and process analysis in order to determine the most effective and efficient way of producing aerospace parts using a very wide mix of technologies including turning, milling, grinding or in-process probing.

Breton competences are ranging from the lightest composite materials up to the toughest special alloys and,doesn’t really matter if the application is around an aero-engine part or a large structure, their vertical gantries provide an answer even to the most specific demands.


HIGH DYNAMICS

There are multiple advantages offered by the architecture of the Breton machines (vertical trunnion tables, large overhead gantries and moving portals) such as reduced footprint, greater  and comfortable accessibility, very high dynamics, thermo-symmetry and thermal stability combined to a user-friendly programming and a low maintenance requirement.



These benefits become even more evident when a single machine is capable of performing more than one task simultaneously in a perfect multitasking approach, a concept in which Breton is well-experienced.

As an example, in its ceaseless research for innovation, Breton has recently introduced two revolutionary technologies that open up new horizons for the machining of aero-applications.

COUNTERSINKING

The heart of one of these is a machining head that can drill and countersink not only faster but also more precisely than ever before. It can be installed on a variety of 5-axis machining centres, such as those of the Breton Matrix and Breton Eagle families.





No special programing is required since automatically 3 accurate probes around the cutting tool come into contact with the surface of the workpiece to detect the real position in the space, directly adjusting the perpendicular direction to the surface and measuring the exact countersinking depth.



All in one shot. It's a unique solution, which has already been adopted by various aerostructure manufacturers who now supply components with a higher degree of accuracy in much faster lead times.

ULTRASONIC CUTTING

Another exciting innovation focuses on the accessories Breton has developed for ultrasonic cutting, ideal for machining core materials with aramid and aluminum honeycomb, for structural components which must be lighter than ever while maintaining their structural rigidity, produced at incredible speed.


Both technologies are automatically managed and are interchangeable with other conventional rotary cutting tools, performing a series of operations with just one machine thus reducing investments, production costs and times, while guaranteeing greater accuracy and more efficient productivity.

INCREASE PRODUCTIVITY

Considering the important existing order backlog in several aerospace programs, the rump-up stage of many others and the extremely positive outlook for the future of the air transportation, there is no doubt that most of the international aerospace players need to increase productivity and be prepared for incoming growing demand.

In such a context  the selection of a reliable and dependable machine tool partner is becoming more and more important every day. If you need a robust supplier granting stability and innovation for the years ahead, Breton is the one.

BRETON MACHINE TOOLS DEPARTMENT





For more information write to mail@breton.it.

Monday, 29 August 2016

Breton, the highlights of Farnborough Air Show 2016

The visit of the italian minister for defense, Roberta Pinotti
We want to use this video to thank everyone who visited our stand in July at Farnborough International Air Show 2016.

All visitors, all customers, all dealers and agents.






Keep in touch with Breton, in the next months we'll have a lot of news regarding our 5-axis machining centers which can be flexibly adapted to your manufacturing requirements.



Thursday, 4 August 2016

IMTS 2016 is just around the corner

Come see us at Booth S-9186 in Chicago (USA) from September 12-17, 2016.

We'll be proud to introduce you all the latest developments and innovations of our high speed 5-axis machining centres.


We look forward to welcoming you at IMTS 2016.

Stand Breton USA @ IMTS 2014


PLAN YOUR MEETING WITH US

Use the Breton USA’s AGENT LOCATOR to plan your meeting with us.
Search your agent here >>

REGISTRATION IS OPEN




For more info about the exhibition and requests about Breton machine tools, write now to mail@breton.it.


Thursday, 21 July 2016

Breton Machine Tools at FARNBOROUGH AIRSHOW 2016








 For info and requests about Breton machine tools, write now to mail@breton.it.
Well, that’s all for today. 
Bye-bye

Sergio Prior

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