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.



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.

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5 axis milling, 5-axis machining centres, aero-engine part, aerospace industry, aerospace parts, breton, Breton machines, high-dynamics, turning

No win without a winning team

For multinational corporations or SMEs, the key is always teamwork, strategic vision and persistence.
Like in the case of Merletti Aerospace and Breton's Matrix 1000. 

(by Paolo Beducci - M&A Meccanica e Automazioni)

Among the classic profiles of Italian family-run businesses we believe some events are more Italian than others, because certain affairs are a more accurate reflection of typical Italian business practice, the will to succeed and the resilience, meaning the ability to adapt to different situations and make positive changes in the organisation when facing challenges.

Incorporated in 1972 by Gianluigi Merletti and his wife Narcisa, Merletti Aerospace was founded under the name of Meccanica Merletti, a general mechanical engineering contractor dedicated to the production of limited series with high value in terms of the exceptional quality of the machining work. 
It's worth noting that Merletti operates in a high-tech industrial district: the Varese industrial area, specifically Arsago Seprio, where the majority of Italian aeronautical companies have their headquarters. It should come as no surprise to learn that Varese is known locally as the " the province with wings” (provincia con le ali). 

AgustaWestland and AleniaAermacchi, for example, are just two names in a long list of companies whose presence has led to the emergence of a high value added industrial settlement. 
From its beginnings, Merletti achieved recognition for its exceptional operational competences and its ability to interact, directly or indirectly, with large industrial concerns, including several companies active in the aeronautical and aerospace industry.

Arrival of the second generation

In the mid-1990s the Merletti husband and wife team realised they needed to address two types of problems. The first concerned the technological strength of the company, while the second was related to the ability to prepare the family business for a future that would no longer be constrained by the need for the active participation of the two founding partners. 
The solution adopted by Gianluigi and Narcisa was to bring their two children (Ruggero and Sabrina) into the business and simultaneously launch an investment plan aimed at modernising the company's capital equipment. 
At that time NC machine tools were making their presence felt (also in smaller companies), resulting in a technological paradigm shift of revolutionary proportions. 

The era of highly skilled lathe and milling machine operators was drawing to a close, giving way to the era of machining tolerances of tenths or hundredths of a millimetre and ultimately, microns. 

Despite being born and raised in a family focused in high precision mechanical engineering operations, Ruggero and Sabrina had followed different career paths that were far removed from the vocation of their parents. The Merletti husband and wife had now started to plan the introduction of a significant new aspect that was proving extremely successful in terms of the times and results. 
Having always focused on Quality in all its operations, Merletti was among the very first small companies to secure EN ISO 9001 certification in 1995, going on to obtain certification in compliance with EN 9100 in 2006.
In the words of Ruggero Merletti – whose role in the family business is to run the Engineering Department and handle technical management – "One of the most significant aspects of our strategy was that at that time many of our customers lacked our qualifications and certifications, either in-house or in their supply chains, so we were perfectly placed to provide the support they needed. In certain cases our company was more highly qualified than the customers we were serving".

Aerospace becomes the core business

The gradual but increasingly massive shift towards the industry that would lead to the company name being changed to Merletti Aerospace, slowly led the Arsago Seprio-based company to focus its operations on increasingly specialised production activities and high-end materials. At this time, the company started working increasingly with special materials such as aluminium alloys, Inconel, high-tensile steels and titanium: all of which, for different and even opposite reasons, call for advanced levels of production expertise. 

Apart from the materials, following a trend that was gaining ascendancy also in the aeronautical industry, over the years Merletti Aerospace specialised in high level machining operations and also in the production of mechanical parts with a range of processes from the procurement of raw materials to heat treatments, construction and dimensional checks, galvanic treatments, surface coatings and assembly of mechanical units and sub-assemblies. 
The entire process also involves the design and construction of machinery for the production of aircraft parts and equipment, completing the offering with full verticalisation of sub-assemblies, including assembly and testing procedures. The result is a fully-developed industrial system that boasts exceptional levels of know-how and skills.

In this panorama, the company clearly needed a design department and machining operations of a level that is greatly superior to the norm. The company's resources comprised a dozen 4- and 5-axis machining centres plus CNC lathes and multitasking machines capable of working with very large size parts for the aerospace industry.

Ruggero Merletti explains, “I believe a company needs to evolve constantly, changing and growing wherever possible. 
As soon you relax and start to enjoy the results already achieved, hard-won market positions start to recede. And in a market like ours, which is among the most competitive in existence today, this requirement becomes an absolute must. That's why we decided to make new investments aimed at growing the business, and in our case it was literally a question of growing, having decided to acquire a machining centre capable of working with larger size parts. This decision was aimed at gaining a foothold in a new market area in terms of dimensional characteristics”

A new push towards the future

Essentially this meant identifying and purchasing a gantry machining centre capable of working on very large parts. 

It was no chance that we decided to opt for a Matrix 1000 by Breton, with axis strokes of 3000x6000x1000mm. 
In practical terms, this decision allows us to tap into new possibilities, especially in the production of structural components, working with high precision on five continuous interpolated axes in order to perform 3D machining operations: basic requirements that are not easily fulfilled by manufacturers of high-end machine tools.

“The best path to follow was to draft a set of specifications – explains Merletti – and then perform a field evaluation of the compatible machines available for purchase. I have to admit that our specifications were highly demanding and difficult for any machine tools manufacturer to meet. After performing an internal selection to narrow the field of potential suppliers, we were left with just four companies, to which we submitted our requests. 
And it didn't end there... the specifications also called for field trials and specific guarantees in terms of presence and assistance – both for the choice and installation of the machine and also during routine machining operations. We awarded a score to each machine and each company, together with assessments ranging from the characteristics of the machines to their presence on the market, the number installed machines and numerous additional factors." 

The solution is Matrix

"We performed a workpiece test. 

The results obtained were all fairly satisfactory, but in relation to certain points Breton was a step ahead of the rest with respect to our requirements. From the  vacuum system to the chip removal equipment – critically important when working with high material removal rates per unit time – up to the electrospindle which, in the case of Breton, offers a power rating of 70kW and maximum rotation speed of 28,000 rpm.” 
Merletti continues "Over the years Breton has developed a preferential path, with collaboration with one of the top electrospindle manufacturers right from the design stage, thus providing our company with a further guarantee that we would be getting a machine tool that is entirely representative of the state of the art.”

One of the first aspects visible when analysing the Matrix 1000/2TK60 Dynamic is the extremely comprehensive enclosure system, an important requirement when working with materials that are difficult not merely in terms of machining work but also in relation to the management of processing residues. The vacuum system is an integral part of the machine, which is also equipped with a 180-position tool magazine. Given the solution adopted, it's clear that Merletti covered all the bases when selecting their new machining centre!
However, that's what it takes if a company plans to keep one... or even two steps ahead of increasingly fierce competition – competition that is starting to feel the effects of the arrival of newcomers from low-cost countries operating in the lower and less remunerative end of the market.

Ruggero Merletti concludes “While we were impressed by the performance of the machine, we realised we'd chosen well once we started the procedure to install the Matrix. Apart from the fact that rather than a simple machine tool we were dealing with an authentic plant presenting a series of complexities also in the installation stage, I was impressed by the fact that Breton's technicians followed the process step by step, displaying a level of dedication that was invaluable for our company. 
The attention we received went well beyond our expectations, including the constant presence of Breton personnel during construction of the foundations, painstaking attention devoted to details, and the maximum availability throughout the process. 

And the assistance was provided by a youthful and dynamic team who displayed great dedication and passion for their work, as clearly reflected in every activity and in the way they went about each task.
It seems to me that apart from offering truly exceptional products, Breton understand that it takes a perfectly coordinated team to win the race”.

For INFO and request about 5-axis machining centre Matrix 1000 Dynamic write now to mail@breton.it. 

Well, that’s all for today. 
Bye-bye
Sergio Prior

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5-axis machining centres, breton cnc 5 axis, Breton Matrix 1.000 Dynamic, Merletti aerospace

HIGH SPEED PRECISION with Breton MATRIX 1000 DYNAMIC vertical machining centre

Breton has chosen to install the high-end HEIDENHAIN TNC 640 numerical control on the renewed versions of the Breton Matrix Dynamic 5-axis machining centres.

(By Claudia Pirotta - TECNE' )

In this edition of EMO 2015, Matrix, the 5-axis continuous high speed machining centre manufactured by Breton is presented to the public for the first time in the renewed version equipped with the HEIDENHAIN TNC 640 numerical control.  

In fact, at the stand you can admire a Matrix 1000 K60 Dynamic equipped with HEIDENHAIN TNC 640 numerical control. 
The operating dynamics (acceleration and movement) of the machining centre manufactured by Breton has always been one of the strong points of this family of machines dedicated to milling medium and large parts from steel, aluminium, composite materials or resin. 

On the improved Matrix Dynamic version, Breton has chosen to install the HEIDENHAIN TNC 640 numerical control for the first time, offering further a performance improvement in terms of chip removal and milling quality.

INCREASED EFFICIENCY
Three years after its launch, the TNC 640 control is now a consolidated product for combined milling and turning applications, and it has the right characteristics to serve the range of machine tools manufactured by Breton. Fast block processing, short control loop cycle time, smooth motion that ensures an accuracy not commonly found in machined surfaces and, not least, fast data transfer distinguish HEIDENHAIN control for High Speed applications. 

In particular, the ADP function, which calculates the maximum feed rate in advance, has been further enhanced in the TNC 640 giving it a strong “look ahead”, with enhanced block reading that allows the machining path to be adjusted in order to optimise it for the 5 axes in terms of machining time and surface quality. 

Tests conducted in Italy have given significant results, confirming that the TNC 640 is specialised for 5-axis machining control. The programmer, in collaboration with the creator of the CAM program, is given the opportunity to decide the most appropriate way to manage and set up the machining. 

The HEIDENHAIN TNC 640 offers even greater opportunities to improve the machining results compared to the iTNC 530. With suitable modifications, tests have shown, a 10% efficiency increase under "normal" work conditions, that is, without taking the machine to its limit.

UNCOMMON PRODUCTION

Breton’s reference target in the machine tools sector is to build “tailored” machines intended for manufacturing high quality, high technology products, generally in small lots. Strong customisation is one of the company's distinctive features: starting from the catalogue range, Breton customises the machines to adapt them to their customers’ production needs. 

In the machine tools field, the company has concentrated on the continuous 5-axis high speed machining centres for the die manufacturing, aerospace and racing sectors. Fields for which machining of materials such as aluminium, special alloys, titanium and composites is required, sometimes with uncommon profiles (just think of the prototypes), characterised by very high surface quality, maximum respect of the design tolerances and first class finishing. 

In recent years, Breton has also paved the way towards gearing, a very delicate niche sector. Large gears, small lots, prototypes or special spare parts that cannot be made conveniently with traditional machines: any of Breton’s 5-axis centres is able to manufacture these parts.

When the finished product requires high technology and surface quality, the HEIDENHAIN TNC 640 control proves to be a winning choice because it enhances the HSC precision machining of the 5 continuous axes. Like all the Breton machines, Matrix has a vertical portal gantry structure, which optimised the machine’s footprint and ensures high precision over the axes’ full travel, thanks to the neutrality of the RAM configuration. Moreover, the vertical configuration aids chip removal and makes access to the work area safe and immediate.

All the heads are developed internally and are integrated with various motor spindles with innovative solutions developed by Breton in collaboration with its suppliers, with various powers and rotation speeds, suitable for machining different materials. 

In particular, the machine on display is equipped with a very high speed spindle, with a nominal power of 70kW, which guarantees a constant machining torque up to 10,000rpm (see graph). This innovative solution guarantees excellent chip removal in the aluminium and aerospaces sectors, embracing the HSM philosophy in full.

The machine has been developed to ensure machining of the highest quality, starting from the spindle and the high-speed milling concept. All the motors in the Matrix have thermostats to limit the heat dissipation. Carefully combining and manually fitting the individual parts that make up the machine cancels structural deformation caused by temperature variations. The bridge travels on columns and guideways filled with Metalquartz®, a compound of resin and aggregate developed by the Breton research centre, that damps the vibrations and helps stabilise the structure.

The build characteristics of the Matrix Dynamic, together with the power of a control like the TNC 640 ensure the machine has better HSM machining performance, offering a valuable instrument to all those working in this sector.

For INFO and request about Breton MATRIX 1000 Dynamic, write now to mail@breton.it. 
Well, that’s all for today. 
Bye-bye
Sergio Prior

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5-axis machining centres, 5-axis machining control, Breton Matrix 1000 Dynamic, HEIDENHAIN TNC 640

A model company

To serve new markets with its aluminium models for foundry applications, Italmodel has turned to 5-axis machining, choosing the technology and support of Breton, in the form of the recent Matrix 800 2T K25.

Everyone knows Italy as a land of art and artists, but what people often overlook is that the concept of “art” can also be applied to neighbouring fields.

Indeed, in the mechanical arena, when you visit a model shop, you can see with your own eyes how technology combines with human ingenuity to create products that reach almost artistic heights.

Italmodel is very much on that level and has been ever since it was founded by Antonio Guarneri. This family firm, where craftsmanship and industrial production combine harmoniously, is now run by the second generation.

From wood to metal  

“Our father set up Italmodel in 1979,” explains Davide Guarneri, who runs the business with his brother Fabio and sister Floriana, “to produce wooden models for foundry applications. Until not long ago, the models required highly specialist, experienced labour. Over the years, technology has made great strides, so much so that in 2001 we bought a 5-axis wood-milling machine. Meanwhile, the business began to diversify: wood is a suitable material for making small batches in the foundry; it is economical but not very durable. For higher volumes, you need metal – like aluminium, although that demands the right tools and a completely different approach in order to be machined profitably. 

Today, with the now-common 5-axis machining centres, all it takes to obtain good results is a skilled worker and the right software in your technical office. The key is in refining your processes, understanding how to get the most from the tools, and relying on the machine manufacturer’s expertise, to gain the “tricks and tips” that are vital for maintaining profit margins.”

At this point, we need to take a step back. 5-axis machining – however you do it (positioning, continuous operation, etc.) – is clearly more complex than using a 3-axis machine.

“From this perspective, despite its limitations, the first machine for wood really opened our eyes: it enabled us to gain confidence with a new way of working,” says Davide Guarneri. 

“And to be frank, with wood, it is fairly easy to patch up a mistake or blemish with filler. Metal imposes other technological constraints and brings potential risks, not least that a 5-axis metalworking machine is not cheap to buy or run. That is why we evaluated our options very carefully, and we chose a Matrix 800 2T K25 machining centre by Breton.”

Increasingly demanding markets 

“Until a few years ago, we could count on a very local clientele, even from Lombardy or neighbouring regions; now, however, we are facing international competition, whose strength is its low labour costs,” adds Fabio Guarneri. “To compete, then, it is crucial to reduce our overall costs without compromising on quality. The only way is to use tools that enable us to cut those costs while maintaining our distinctive high standards.”

5-axis technology has become indispensable for Italmodel.

“To complete certain jobs, it is essential to have a 5-axis machine like Matrix; without one, you are forced to turn down some complex projects. Obviously, saying ‘no’ to a potential client is not an option. So being able to rely on a powerful, flexible, high-performance machine is not just a means of boosting manufacturing profitability – it is the only way to stay in business.”

“Of course, just putting a machine in your workshop is not enough: to get the most from it, you need the right software. We have loaded the Matrix model into our CAD/CAM system and used it for simulations: moving from 3 axes to 5 dramatically increases the number of parameters in play. We use the machine in various ways: for positioning, with the 4th axis moving, and for continuous 5-axis machining.

Depending on the workpiece, the production requirements or the desired final quality, it is important to choose the most suitable mode. Even with complex surfaces, often all we need do to finish the job is wipe the workpiece clean with a cloth – as long as you selected the right working mode, as I mentioned.”

Reliability and performance   

Matrix 800 2T K25 is an interpolated 5-axis vertical continuous machining centre for working different types of material, from steel to aluminium and composites to resins.
For a work area of 2,000x1,600x800 mm (X/Y/Z), it offers a compact footprint and high-level dynamic performance, with maximum axis feed rates of 40 m/min and acceleration of up to 3 m/s2.

The typical Breton dual-drive gantry structure provides a large work area allowing the operator full freedom of movement, in strict compliance with safety standards. Matrix 800 makes it possible to position and machine even large workpieces with ease, combining excellent reliability and safety features with optimum performance. Operators appreciate the Matrix 800 even more for its rigidity, courtesy of the electro-arc-welded heat-treated structure made entirely of steel with suitable stiffening ribs and other reinforcement.

Continuing Breton’s technology traditions, the twist head with continuous rotation of axis C and axis A ideal for machining undercuts with a ±105° rotation enables even complex workpieces to be machined at high speed.

Italmodel uses its Matrix primarily to work aluminium and resin components, but that belies its full capabilities.

“We have made various steel components for other industries, and we have been pleased to note that the machining quality is just the same, even for more stubborn materials, as the extra power kicks in,” confirms Davide Guarneri. “Precision working and finishing is assured, not only by the tight construction tolerances but also by the thermal stabilisation and by the software that compensates for thermal expansion in the electrospindle and for dynamic errors arising as operating conditions vary. The liquid tool coolant and the air for cleaning the tool taper flow within the electrospindle.”

The extra dimension: service   

When a company like Breton sells a machine, its responsibilities do not end there. “It has been a considerable investment for us. Initially, we feared that we had bitten off more than we could chew,” confides Davide Guarneri. “But we soon realised that Breton’s service, both pre and post sale, would give us timely, expert answers to all our queries. For example, I had never seen remote support in action before. A while ago, the coolant pumps would not work: the Breton technicians connected to the machine and noted that the problem was caused by a microswitch on the door failing to make proper contact, thus preventing the machine from operating. 

We found an accumulation of dirt at a particular point; after cleaning, the machine restarted immediately. The total downtime was less than 2 hours! When you have a delivery deadline approaching, these are the details that make the difference between finishing on time and being late.”

“When we signed the contract, we had the chance to visit the Castello di Godego works in Treviso,” remarks Davide Guarneri. “Seeing how they build and assemble the machines was reassuring, because it showed us just how much dedication goes into making the product that will then be installed in a customer’s workshop – the same dedication that we put into using it.”

Many thanks to Andrea Pagani and TM – Tecnologie Meccaniche – for the material provided.

Click here for more INFO e price.

Have a nice day

Bye-bye

Sergio Prior

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5-axis machining, 5-axis machining centres, aluminium, breton matrix 800, continuous 5-axis machining, resins