New Matrix 1000: ideal for mould&die makers

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.

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 more” - difficult to achieve, but not impossible. In fact, Breton designers were able to achieve better performance at a lower price.

Designed for the 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.
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 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 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 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 thermo-symmetric 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.).


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.

For more information please write to: mail@breton.it

Thank you for your attention.
See you soon,

Sergio Prior

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breton matrix 1000, die manufacturing, mould

Breton at EMO 2017 with fully redesigned machining centers!

The two main products that Breton will present at the next version of EMO Hannover are the latest versions of the ULTRIX 1200 EVO and MATRIX 1000, fully redesigned machining centers to ensure even better performance for our customers.

COME TO THE FAIR!

Breton offers you a free one-day entry to EMO 2017! To register your entry, fill out with your details the form on this page:

http://www.breton.it/landingpage/en/emo-2017

You will receive the link to complete your registration by email later.

For more details we are waiting for you at EMO 2017 in Hannover, from 18 to 23 September.

[Hall 13 - Stand C 24]

Regards,

Sergio Prior

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breton matrix 1000, emo hannover, matrix, Ultrix 1200 EVO

Breton launches Matrix 1000 and Ultrix 1000 at EMO 2015 in Milan

Good morning,

Our solutions for your success: we look forward to seeing you at the exhibition EMO 2015, in Milan (Italy), from 5 to 10 October
[Hall 1 - Stand D 19].

Come and see closely the two Breton's CNC machining centres:
MATRIX 1000 K60 DY and ULTRIX 1000 RT HD.

BRETON MATRIX 1000 K60 DY

The perfect solution for aerospace industry. A 5-axis high-speed machining centre for milling large-size aluminium components equipped with an electrospindle that can machine workpieces up to 6 meters in length (removal capacity: 11000 cm3/min). 
Click on the image to read more. 

BRETON ULTRIX 1000 RT HD

Are you looking for a machining centre that combines milling and turning? 
Your solution is ULTRIX 1000 RT HD, the multitasking machine for working superalloys, steel, aluminium and composite materials, already chosen by first-class energy, aerospace and gear industries. 
Click on the image to read more. 

Well, that’s all for today. 

Bye-bye

Sergio Prior

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5-axis high-speed machining, aluminium, breton matrix 1000, breton Ultrix, CNC machining centres, Composite materials, EMO 2015, EMO Milano, steel, superalloys

5 axes in coffee with Breton MATRIX 1000 vertical milling cnc machine

To reduce cycle times, maintain very strict tolerances and optimize machinings, companies are increasingly turning to 5-axis machines tools on which after the blank has been loaded and clamped the finished part can be produced without any further repositioning.(By Giancarlo Giannangeli for TM- Teconologie Mecaniche)

Opem Spa started operating in Parma in 1974 in the field of industrial foods products weighing; from the beginnings no effort has been spared in continual search for innovative solutions. Enhancing performance and quality has always been a primary goal, in a philosophy that has allowed the Emilia-based company to achieve undisputed levels of technological excellence. Opem therefore has gradually gained ascendancy in the packaging industry, refining new machines that are now being sold all over the world.

Today coffee is the driving line, occupying first place in terms of sales, but the company also produces packaging lines for tea, barley coffee, herbal infusions, ice-cream mix powders, milk powder, spices and biscuits. Coffee is packaged in cans and pouches, in beans or ready-ground, although the lion's share currently lies with coffee pods. In this field Opem is the absolute world market leader, as confirmed by Fabio Binacchi, founder and president of the north Italian company.

«95% of our output is exported; we face fierce competition from German groups, but despite our relatively small size we are hailed for the quality of our products and have established an enviable reputation. We also have several major customers in Germany and despite the renowned German predilection for domestic production we recently supplied additional lines to several German companies that continue to insist on using our products. This seems to confirm that our consistent strategy of placing customers at the center of our development process has allowed us to build systems that offer the utmost productivity and reliability - the key quality prerogatives for industrial plant. As a dynamic SME we place the maximum emphasis on flexibility and our ability to supply completely bespoke systems».

The company was recently  classified by  Ucima (automatic machinery manufacturers association) and ranked number one in Italy in terms of net operating income and sales margin, surpassing all the big name manufacturers operating out of Italy's packaging valley in the Bologna area. On the European level the company came in second, preceded by a single German operator.

A high precision stable machine

Today, Opem operates out of a spacious factory where all systems are designed and built internally. The company has always insisted on keeping all stages of the development cycle in house, from the preliminary analysis preceding the design stage to construction of the various components and final assembly.
«Our focus is to guarantee the maximum quality levels at all times, so we consider it essential to retain full control of each stage of the process. This allows us to make instant priority changes whenever necessary without having to defer to contractors that, however reliable and well-intentioned, are unable to match the speed of response that we can guarantee with our own facilities».
That's why we have a fully-equipped workshop to build all the non-commercial components used in our systems directly in-house. To streamline and optimize our operations we recently purchased a Breton Matrix 1000 5-axis medium-large gantry center offering high speed machining and impeccable performancei.

For example, the carriage and beam travel on generously sized recirculating roller guideways that ensure high precision and stability: all axes are moved by a ground recirculating ball screw with a double preloaded ball nut assembly; position reading tasks are performed by optical linear encoders. Breton devoted special attention to controlling thermal expansion by cooling the ball nuts directly rather than merely cooling the ball screws, thus radically mitigating heat propagation directly at source. The axes are powered by the latest generation brushless servomotors controlled by digital drives.

Increasingly extreme performance levels

Matrix 1000 is a machining center for milling complex 3D shapes that must be machined to high precision and that call for continual axes interpolation. It may seem superfluous in a company that “simply” produces packaging systems, but in fact these automatic lines are composed of increasingly complex machines that offer impeccable performance in terms of operating speed, reliability, and repeatability of results through time. Customers in the industry are currently marshalling their resources because they need to boost productivity levels to produce ever higher numbers of packs per unit time, resulting in a race among suppliers to offer ever faster machines.

The productivity of the lines produced by Opem varies from system to system, but output can easily reach 1,200-1,300 pods/minute, each individually weighed and sealed in plastic wraps. An impressive production rate that makes it hard for a bystander to even see the products in the blur of motion they hurtle along the conveyors. Indeed, the only way to actually see products in transit is to observe the production flow under strobe lighting!
This exasperation of packaging speed calls for micrometric precision in the construction of moving parts, which must be meticulously crafted to obtain infinitesimal mating tolerances. Even if 5 continual axis machining is performed rarely in the Opem workshop, the 4 and 5 positioned axes have become a constant, especially in relation to large size workpieces.
Maintenance of precision can be guaranteed only when the blank part is positioned in the machine just once.

«Milling on several faces, angled chamfers, drillings and many operations on a single component are all part of the routine today and we need to perform all these processes on the same machine. Clamping is a single process; all operations are performed in sequence and the part is fully machined and finished. The absence of additional external operations on the part once it has been positioned on the worktable results in compliance with tolerances in each dimension that were hitherto extremely difficult to achieve and called for painstaking set-up procedures. Today we can be absolutely certain that precision requirements are met consistently».

Also time savings resulting from faster throughput times have been maximized thanks to the Matrix 1000.
«With respect to the past, when we had to unload parts and then reposition them, machining times have been significantly reduced. In addition, a powerful machine like the Matrix, with its impressive performance credentials, greatly assists us in making heavy duty components».
Another of the reasons that led to the choice of such a monolithic machine is the size of the worktable, which makes it possible to clamp both bulky side assemblies or even several parts in different areas of the worktable to be machined in succession and without interruption.

Parameters for high speed

Before choosing the Matrix 1000, the Emilia-based company management did their homework carefully: «We found a large number of high quality machines on the market, but we preferred to go with an Italian product made by a high-end builder. Price is not the critical factor for our company: the characteristics we are focused on are precision, ruggedness and, above all, the level of service received. In fact, working with the machine manufacturer's technical team a series of special tooling systems were developed in accordance with adequate parameters for this type of high speed machine. Our collaboration with Breton made it possible to refine chip removal technologies and strategies, identify the best tools and optimize the machining processes. All cycle times have been significantly reduced, both for roughing and surface finishing».

The selected tools are stored in a spacious magazine that ensures prolonged operation of the system without intervention. The magazine is installed outside the work area to keep the tools clean and ensure the maximum level of reliability through time. The cast-iron fork head is particularly effective, imparting both structural stiffness and absorbing machine vibration. The model installed in the Opem works is equipped with Direct Drive motors and a thermally stabilized spindle.

A versatile machining center

Matrix 1000's massive frame and high performance make it the ideal solution for a range of industries: aerospace, automotive, tooling and design. To meet all machining needs, Breton can configure the machine specifically in accordance with customers' needs; the standard version is equipped with a large working area, although it can be configured with two separate work areas for tandem machining. The machine affords optimal accessibility and visibility of the work area thanks to its large front doors and gantry structure with travelling beam.
One particularly interesting feature is the structural solution invented and patented by Breton: heavy-duty shoulders built using innovative Metalquartz technology, i.e. an arc-welded and stabilized steel sandwich structure with ribbing embedded in a quartz composite polymeric matrix. This exclusive technology assures the utmost structural rigidity and vibration damping, which guarantees a better surface finish and longer lifetime of the milling tools.
Matrix is not designed simply for machining steel parts: it can also work with composites and resins. The machine can be equipped with an efficient dust extraction system on the spindle nose and roof-top bellows that completely seal the work cell, segregating the machining zone from the surrounding environment.

For info and requests write to mail@breton.it.
We’ll get back to you promptly.
Well, that’s all for today, thanks for your attention.
Bye-bye
Sergio Prior

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5-axis, breton matrix 1000, machining center for milling, machining for steel composite resin

Fast removal with Breton Matrix 1000/2T Dynamix

The gantry machining center with moving cross beam  Matrix 1000/2T Dynamix was designed and built to respond to high-speed machining requirements in mold-and-die and styling applications. 

Conceived for large complex parts, with its distinctive properties of rigidity and dynamics, it can handle several types of parts at the highest speed, with excellent removal capacity. 

The speed of linear axes up to 60 m/min, the Direct Drive head with rotation speed up to 100 RPM and the C axis with continuous rotation offer outstanding capabilities for profiling complex workpieces with 5 continuous axes ensuring and guaranteeing maximum machining precision and performance.  

The direct drive twist head, which can be positioned at any angle thanks to the powerful hydraulic brakes, uses fitting spindles up to 40 kW, with 51 or 10 Nm torque and rotational speed up to 28,000 RPM. 

Different configuration options – with Z from 1,000 mm, X from 2,200 mm and Y from 2,500 to 6,000 mm – offer the perfect solution for machining medium and large size workpieces in steel, aluminum, resin and composite materials.

The closed structure and drive assemblies mounted on the top part of Matrix 1000/2T Dynamix ensure maximum operator safety and maximum machining precision and reliability. 

Machining precision and quality are further enhanced by the thermal symmetry of the machine structure and by the thermal stabilizing system, which stabilizes the temperature of the ball nuts, Z-axis bearings and axis drives, and maintains it at the same temperature of the machine structure during high-speed machining operations.
Click here for additional info about Matrix 1000/2T Dynamix.
Write to mail@breton.it to ask for an estimate
By-by

Sergio Prior

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breton matrix 1000, breton vertical machining centre, gantry machining center, mold-and-die and styling

MATRIX 1000 - Ideal machine for aerospace, automotive and die-manufacturing

A competitive solution 
High-speed precision machining centre for milling complex three-dimensional work-pieces which require accurate machining and continuous axis interpolation.

MATRIX 1000 is the ideal solution to satisfy production requirements across a multitude of industrial applications from aerospace industry to automotive, die-manufacturing and design.

Wide choice of configurations for customized performances
Various solutions for the best machine configuration to satisfy each need:
- Standard model with one working area
- Model with two working areas for pendular machining.

Easy access and perfect visibility
Great accessibility and visibility of the working area thanks to the machine gantry structure with moving bridge and wide frontal doors.

High precision, dynamics and speed with 5 continuous axes
In order to ensure high performances, the new MATRIX 1000 is provided with heavy-duty shoulders manufactured using the ground-breaking Metalquartz technology.

Shoulders consist of a sandwich structure made of stabilized arc welded steel, whose ribbing is embedded in a quartz composite material with a polymeric matrix. 
This exclusive technology ensures a very high structural rigidity and vibration damping, which guarantees a better surface finish and a longer service life of the cutting tools.

A superior head
The electrospindles offer always the best machining performance thanks to the cast-iron fork designed head which offers structural rigidity with efficient vibration damping properties. The most high-performance machining centres are provided with Direct Drive motorized heads.

High-speed, Performance and Precision
The carriage and beam travel on properly dimensioned recirculating roller guideways ensure machining precision and stability. Axes are moved by a ground ball screw and double preloaded ball nut assembly.
Maximum axis precision is achieved thanks to the micrometric technology applied. Axes are powered by digital drives and ultimate generation brushless servomotors.

Wide choice of electrospindles
The MATRIX 1000 machining centre can be supplied with a wide range of electrospindles depending on the type of material to be machined. Machining precision is always guaranteed by the thermal stabilising system which consists of a special software designed and developed to compensate natural thermal expansion in the electrospindles when machining conditions vary.

M38/28
A 20 kW electrospindle with a 38 nm continuous torque in S1 and 28,000 rpm is the ideal choice for high-speed machining requirements for steel and light alloy from rough milling to precision surface finishing operations.



M51/28
Electrospindle featuring a power of 40 kW, continuous torque of 51 Nm in S1 duty and 28.000 rpm: the ideal choice for customers requiring high-speed machining on either steel or light alloys, from rough-machining up to precision finishing.



M100/18
Electrospindle featuring a power of 40 kW, continuous torque of 100 Nm in S1 duty and 18.000 rpm: smartly performing any machining operation on either steel or light alloys, from rough-machining up to precision finishing.

Simple and reliable tool magazines
According to the various models, wheel-type or chain-type tool magazines with fast manipulator to reduce tool changeover times are available. Installed outside the work area and therefore free of dirt, these tool magazines ensure the greatest reliability over the time. 

They can be equipped with an automatic chip coding system containing tool data and information.

Dust extraction and ceiling enclosure

When machining composite materials and resin, MATRIX 1000 can be fitted with an efficient and effective dust extraction system which is installed on the spindle nose. In addition, top-roof bellows can be fitted to the machining centre creating a complete enclosure isolating the machine from the surrounding areas. 

Different models of dust extraction systems are available to satisfy any customer’s requirements.

The ideal cooling system
Depending on the type of machining, the tool cooling system can use a coolant liquid which flows inside and outside the spindle (60 L/min) with fixed or variable (up to 70 bar) internal pressure, or incorporate a spray mist system, or simply use compressed air.

Monitoring and in-process inspections

MATRIX 1000 can be supplied with a laser tool presetter and a radio frequency probe for acquiring work-piece size and coordinates.

So, why don’t you request a quotation for a MATRIX 1000?

Write to mail@breton.it

By-by

Sergio Prior

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aerospace machining, automotive machining centre, breton matrix 1000, breton vertical machining centres, die manufacturing

Breton vertical machining centre MATRIX 800 and MATRIX 1000 - ideal solution for moulds

hello,
today I'll show you how our high speed vertical machining centres Breton MATRIX 800 and MATRIX 1000 are used excellently in the machining of the molds.
1 - Vertical machining centre MATRIX 800

2 - Vertical machining centre MATRIX 1000

For more INFO and price write to mail@breton.it.
We’ll get back to you promptly.
Well, that’s all for today, thanks for your attention.
Bye-bye
Sergio Prior

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breton cnc 5 axis, breton matrix 1000, cnc milling machines, high speed cnc, matrix 800, vertical machining centre