Driven by Innovation. March 28th

Transcription

1 Driven by Innovation March 28th

2 Driven by Innovation 1963: Breton was founded by Marcello Toncelli Today 580 people 81,000 square meters of premises of which 40,000 square meters are covered. 2

3 Driven by Innovation With its widely spread sales network Breton sells its machines all over the world It holds exclusive patents and technologies in the stone working and composite stone production More than 100 Breton-Stone plants currently work in the world Breton is also leader in the tooling machines business, very well known for the quality, reliability, and performance of its products. 3

4 Driven by Innovation Aerospace Earth quality standards are not enough on Air. Breton offers Airspace standards. 4

5 Driven by Innovation Automotive Special field, special Breton solutions. 5

6 Driven by Innovation Energy Efficiency makes the difference in the today s market. It makes a huge difference in the Energy field. 6

7 Driven by Innovation Breton will change your numbers: Cost reduction Downtime reduction Operational costs Production performance General Mechanics Efficiency is the key advantage. 7

8 Gear manufacturing on 5 axis tooling machines A Breton solution for gear manufacturing 8

9 SPECIFIC KNOW HOW QUALITY REQUIREMENTS DELIVERY TIME 9

10 Conventional processes require purpose dedicated machines Small production batches are not compatible or profitable with conventional methods Large diameter gears (>600mm) require very expensive machinery and tooling Tools are very specific and expensive, as they depend significantly from type of gear and geometry Design to market lead times are long as they are strongly influenced by tools development and manufacturing Non standard geometries are very difficult to manufacture Gears development requires several prototypes Development process is narrowed by equipment available Few manufacturers hold proprietor solutions 10

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12 Structure Metalquartz fill Manual scraping of all critical couplings Very effective Cooling devices 12

13 Concrete fill Metalquartz fill The same thermal expansion as metal means that fluctuations of Room Temperature Structure Temperature Work/piece Temperature are not generating uneven stresses, therefore no vibrations 13

14 <<< Thermo-Stabilized body Vibrations controlled through dedicated accelerometer >>> High / low pressure cutting coolant available + compressed air blast at the tool-tip 14

15 With ULTRIX and EXCEEDER not only you can manufacture several different shapes, but also you can mill or turn, thus becoming More flexible Quicker 15

16 Best fit procedures TAO Teeth accuracy optimizer algorithm Dedicated pitch error check cycle 16

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18 BRETON took advantage of its experience and know how in high accuracy multipurpose machining centers BRETON acquired the required internal competence BRETON set up a partnership with KISSSOFT, leader in Design software for gears and transmissions for construction vehicles, Formula 1 cars, cableways etc. BRETON developed a specific CAM application dedicated to cut and measurement of pinions and gears BRETON has already identified wizard guides for tools selection and manufacturing of the different gears typologies BRETON Software is modular ( open doors ) 18

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21 Geometry Definition CAD/CAM application Manufacturing INTEGRATED GUIDES 21

22 Geometry Definition CAD/CAM application Manufacturing Powered by Powered by Gear Specs (Gleason, Klingelnberg or direct input) and Nurbs, Teeth Profiles Measurement Grid ISO file to machine 22

23 Geometry Definition CAD/CAM application Manufacturing 23

24 Geometry Definition CAD/CAM application Manufacturing Breton Gear DESIGN SW is made of: Breton KISSSOFT for bevel and spur That generates the basic nurbs Breton Gear CAD Used to manage the surface and apply: Chamfering Mirroring Topological modifications and measure differences between surface and measurement grid 24

25 Geometry Definition CAD/CAM application Manufacturing KISSSOFT and BRETON have established a strong partnership to develop an exclusive professional tool that can deliver to BRETON customer precision and reliability in the geometry definition Breton KISSOFT for bevel and spur is powered by KISSSOFT and generates a precise and effective model to be transmitted to Breton Gear CAM application. But there s no problem in acquiring nurbs generated through third parties design Softwares! No more need to rely on other manufacturers spec sheets, software or tools! 25

26 Geometry Definition CAD/CAM application Manufacturing Breton KISSSOFT for bevel and spur generates the gear geometry (nurbs) starting from specs provided. 26

27 Geometry Definition CAD/CAM application Manufacturing Basic geometry generated can be analyzed in detail thus letting the user determine fine adjustment parameters in terms of profile Crowning, pressure angle, twist 27

28 Geometry Definition CAD/CAM application Manufacturing Breton Gear CAD can then apply heel and toe chamfer 28

29 Geometry Definition CAD/CAM application Manufacturing Breton Gear CAD can also apply semi topping chamfer 29

30 Geometry Definition CAD/CAM application Manufacturing Breton Gear CAD can manage the transition area between root (even when protuberance is applied) and flank in a very fine way 30

31 Geometry Definition CAD/CAM application Manufacturing The convex envelope of meshing contact points between drive and coast sides is built Each individual point of a measured-point grid is compared with the flank surface and orthogonal distance is measured. The adjustment process is iterative and can be repeated until the two meshing surfaces have the desired contact pattern This process can be very useful in the reverse engineering of known gear data sheets or gives the chance to develop high performing gears with a desired contact pattern. 31

32 Geometry Definition CAD/CAM application Manufacturing 32

33 Geometry Definition CAD/CAM application Manufacturing With BRETON solution you don t need a dedicated CAM Office CAM software reside on board, with a very innovative touch interface 33

34 Geometry Definition CAD/CAM application Manufacturing Breton Gear CAM acquires the geometry generated by Breton Gear DESIGN. 34

35 Geometry Definition CAD/CAM application Manufacturing After analyzing and elaborating the input geometry, Breton Gear CAM (powered by Rhino and Rhino NC) supports the end user in the tool selection activity. 35

36 Geometry Definition CAD/CAM application Manufacturing Breton Gear CAM generates the working paths for the tools in a sequence 36

37 Geometry Definition CAD/CAM application Manufacturing Breton-Gear CAM calculates tool paths for pre-finishing and finishing working. VIDEO 37

38 Geometry Definition CAD/CAM application Manufacturing Hardening determines distortions that become evident when comparing finishing result on different teeth. Repositioning in the machine is performed through a best fitting procedure that minimizes the effects of distortions. A smart algorithm called T.A.O. (Teeth Accuracy Optimizer) calculates the sequence of teeth to be worked by keeping into account the progressive tool wear, and proposes the tool change accordingly, or foresees a number of tool changes as a function of the geometry being worked. 38

39 Geometry Definition CAD/CAM application Manufacturing The manufactured surface can be compared with the measurement grid previously generated by Breton Gear DESIGN. 39

40 Round-end mill on a 5 axis tooling machines is strongly competitive versus traditional machining when gear diameter work-piece is larger than 300mm. Thanks to its machines precision, stiffness and high torque performances BRETON can also provide a specific solution for smaller diameter gears, completely integrated in the software suite supplied. A face milling process is available, to manufacture gears with 60 to 250 mm diameter, and it s fully controlled through the gear suite. 40

41 By integrating in the new Breton Gear suite all procedures to generate required tool paths, BRETON can transform its machine in a face milling gear machine. 41

42 Geometry Definition CAD/CAM application Manufacturing 42

43 From theory to reality the application BRETON machines use tool paths generated in order to manufacture high precision gears, thus delivering reliable finished products to our customer. 43

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47 Thank you for your attention 47