Iskar makes improvements in the turning of medical device parts

The demand for precision medical components is growing worldwide, especially for orthopedic and dental implants. The aging of the population has had a certain impact on this; the longer human life, the more demand for medical components.

What followed was competition in this high-end field. Suppliers involved in this industry need not only the ability to perform efficient, high-precision machining of difficult-to-machine materials, but also the ability to provide innovative prototypes of new products, adapt to rapid product changes, and enable small-volume production. Processing such expensive, difficult-to-machine materials with short lead times allows suppliers to make almost no mistakes. To stay competitive and profitable in this area of ​​expertise, you must be in one step!

The good news is that tools designed specifically for the rapid, high-quality processing of medical products have been developed. Choosing the right tool, or even replacing the original tool directly, can double the machining efficiency or cutting edge life, better chip control, and eliminate deformation problems when machining thin-walled parts or difficult-to-cut parts.

For example, when a Swiss dental component manufacturer manufactures small parts, the blades often fail prematurely due to chipping or cutting edge breakage and cannot effectively predict the time to failure. The average life of the cutting edge is 90 parts, but the number of parts machined by the cutting edge is too different, so that the "average life" of the cutting edge becomes meaningless. Therefore, this process requires the operator to pay attention to it at all times.

After switching to the Isca PVD coated pentagonal blade (PENTACUT), the blade is clamped to the toolholder by screws. The high-rigidity clamping makes the number of workpieces per cutting edge more than twice that of the original tool, reaching 250 pieces. And the processed surface finish is higher. The failure of the cutting edge of the insert is gentle and predictable for normal cutting edge wear, as judged by the deterioration of the surface quality of the machined surface. This means that this process can be run unattended. The key to improvement comes from the high rigidity of the blade, which makes the blade highly positioned.

3 commonalities

In the processing of medical parts, metal materials are removed by more than half, which is often overlooked in the turning of medical parts. Although the parts may be small, the metal removal rate is relatively high. Whether on small Swiss automatic lathes or small turning centers, turning of medical device parts often means machining a variety of stepped shaft parts from solid bars. The weight of the machined parts is much smaller than the blank.

Another commonality in the machining of medical device parts is that the material being processed is often difficult to machine. Mainly for high viscosity stainless steel, nickel based alloy, long chip titanium alloy, high temperature alloy, hardened steel and so on. Because when selecting medical component materials, it is often preferred to have biocompatibility, corrosion resistance, and high strength, rather than the machinability of the material.

The geometry of the workpiece also increases the challenge of machining. When processing thin-walled pipe fittings, especially when machining some atypical aluminum medical device components, if the cutting edge is not sharp enough, the tendency of the parts to deform is very large. Many of the workpieces are asymmetrical, and complex curves are not conducive to secure clamping. This requires that the cutting force be as small as possible to ensure that the workpiece is not deformed during cutting. In particular, some workpiece materials with a large shrinkage need to be adjusted to achieve a suitable cutting speed.

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