Breton Shapemill - the perfec 5 axes stone working centre for marble, granite and engineered stone ~ Fabshop machines

Monday, 25 November 2013

Breton Shapemill - the perfec 5 axes stone working centre for marble, granite and engineered stone

Monday, November 25, 2013 No comments

Breton Shapemill - CNC milling centre with 5 interpolated axes designed for cutting, contouring and turning operations.

Breton Shapemill is a CNC milling centre designed for contouring, cutting and turning with five interpolated axes.

• “rapid” displacements ofF up to 40 metres per and a fixed work-table offering users the possibility of multiple and complex machining operations which would otherwise require several machines:
• shaping of blocks or billets utilising a saw blade to obtain large size workpieces with complex shape.
• shaping and creating recesses utilising milling tools.
• contouring utilising shaped tools.
• cutting slabs and billets into workpieces utilising a saw blade.
• turning of columns with shaped profiles or machining of columns to create a twisted effect all along the surface.

Shapemill stands out for performance
• “rapid” displacements of up to 40 metres per minute;
• giant work-table sizing up to 4.000x3.500 mm
• powerful high-frequency spindle of 36 kW;
• max. diameter of the cutting saw blade: 1.000 mm;
• “C” axis rotation: ± 200°;
• “A” axis rotation: from 0° to +115°;
• “X” axis travel: 137.8 / 157.5 in;
• “Y” axis travel: 110.3 / 216.5 in;
• “Z” axis travel: 47.2 / 63 in;
• possibility of using various saw blades, shaped tools, drills, millers, etc.;
• automatic tool-store with 27 positions + (optional) 2 positions for the saw blade.

Shapemill stands out for its structural features:
• Steel work-table secured to the ground, with aluminium top with recesses for mounting fixtures to secure the work piece in place.

• Beam with “gantry” movement along the shoulders (“X” axis) on ground guides and roller sliding block assemblies; the drive assembly consists of a pinion-and- rack system with rack precision to hundredths, with 6 DIN 3961 Alpha quality grade, and precision reduction gears with Alpha backlash adjustment system; the motorization is by Siemens digital brushless-type motors.

• Spindle carriage manufactured from iron casting and moving on roller sliding block assemblies ( “Y” axis); the drive assembly consists of a precision pinion-and-rack system powered by a digital brushless-type motor. The spindle steel cylinder (“Z” axis) is positioned vertically on the inside of the carriage and is moved by a ball bearing screw / preloaded lead nuts / digital brushless-type motor system. Provided with a pneumatic balancing system.

• Birotary head for interpolated 5-axis machining. The head has a symmetrical structure and consists of two main structural elements, the first (“C” axis) is fitted with a Schleifring slip ring system for ± 200° rotation around its own vertical axis and the second element (“A” axis) rotating from 0° to +110° and housing the high-frequency spindle. Rotation transmission are provided by brushless-type motors.

• 6-pole 36 kW high-frequency spindle, cooled by a closed circuit electric-cooling system, which has a rotational speed of up to 6.000 rpm and a steep torque curve so as to supply the maximum power even when rotating slowly (e.g. with a 39.4 in ø saw blade at 1.000 rpm, the maximum power is supplied). The high-frequency spindle is fitted with a HSK-B80 conical coupling for the milling tools and saw blade and provided with an internal and external tool cooling system.
N.B. saw blades with diameters of 31.5 in and over must be secured to the spindle manually with a flange.

• Linear tool magazine with 27 cells.

• Store for saw blade with a max. diameter of 23.6 in, secured to the side shoulders, for 2 positions as a maximum (optional accessory).

• Lathe for producing columns and twisted effect details with workable sizes: ø 42.5/63 x 126 in (optional accessory).

• Frontal protection barrier consisting of a series of sliding doors with manual opening; doors are made from structure and are provided with wide inspection ports. The rear part of the milling centre is closed by a set of steel plate panels.

• Siemens Sinumerik 840D SL: the latest digitally-controlled computer numerical control system, with PC architecture and a PC unit utilising Windows as operating system, with Windows user- friendly interface and fully-developed software for work program management.

• Control console mounted on a mobile pendant structure and equipped with a 15-inch touch-screen colour monitor, a joystick to easily move the motorized working axes movement and a USB port for data transfer.

• Portable mini console, wired to the main control console, to duplicate the major controls (axes management + hand-wheel, emergency shut-down, etc.); this portable mini console allows the operator to be close to the piece to be machined thus controlling directly some delicate machining operations.

• Electrics and utilities are housed in two cabinets with IP54 grade of protection and cooled by an air conditioning unit specially designed for a maximum external temperature of +45°C.

• Superior quality components:

• racks with precision up to hundredths and 6 DIN 3961 Alpha quality grade
• precision reduction gears with Alpha backlash adjustment system
• Siemens digital brushless-type motors
• Siemens CNC unit

Shapemill Teleservice

An Internet connection is required in order to ensure an effective technical support in case of need.

Software for simulating work cycles

This software allows to simulate “Shapemill” when working by dividing the machining centre into different parts: machine structure, axes, spindle, tool-magazine, tools. The software imports the file generated by the CAM program (ISO code) for the piece to be machined and simulates the entire machining cycle, thus detecting any possible impact which may occur.

BretonSmartCam software for 3D programming

BretonSmartCam software is a CAD/CAM integrated environment enabling to create complex surfaces which can be subsequently machined (using the integrated CAM) by numerical control milling and cutting centres with 5 interpolated axes. This software, with a user- friendly interface, runs on Windows.

• Automatic tool control (optional accessory).

It consists of a laser system for measurement to hundredths of the tool profile (installed on a shoulder of the machine) and of a software that automatically aligns the profiles of the series of tools that polish the edge.
This software can also check the consumption and efficiency of each tool.