Medical parts, especially orthopedic implants and prostheses, are a major growth point in small parts processing.By 2050, there will be three times as many people over the age of 65, who account for the largest share of the market for implants.
The medical device industry is growing dynamically and has become an important channel for tool growth.The increase is based on increased longevity in western and Asian populations.The introduction of plastic surgery into the market has also contributed to the continued growth of the medical device industry.Manufacturers also continue to look for better turning centers and tools to improve their competitive edge.
Processing requirements for medical devices
Processing equipment needs to be able to process small and complex parts made of difficult-to-process materials, such as titanium alloys or stainless steel, that require high precision.Working with bone and joint replacements is also complex.Because of the poor cutting properties of the processed material, the blank is usually a rod, which means that a large amount of metal needs to be removed.As a result, some of the parts are cast to look like the finished product, but this adds to the hassle of making complex and expensive fixtures.
Another factor that increases machining complexity is tolerance range.This has undoubtedly promoted the development of processing technology and solutions to improve the competitiveness and production efficiency of smes in processing medical devices.Advanced turning tools, combined with cutting-edge alloy grades, innovative geometry and chip groove design, ensure the processing of complex shapes, while ensuring the tolerance range.
90% of the implanted parts of medical devices are made of Ti6Al4V titanium alloy.Although stainless steel is also used, titanium alloys have a better strength-to-weight ratio and adhere to body fat, making surgeons more willing to use titanium implants.Due to its light weight, high strength and high biocompatibility, titanium alloy 6al-4v has become the most commonly used material for medical implants.Titanium implants do not conflict with mri and ct images and do not interfere with the relevant operations.Titanium alloy 6al-4v is commonly used in the manufacture of hip joint, bone screw, knee joint, bone plate, dental implant and spinal joint.In recent years, though, the use of cobalt and chromium alloys has also increased.
The cutting force of titanium alloy is higher than that of steel.Under the same hardness, the metallurgical properties of titanium alloy make its metal cutting performance worse.Compared with the common processing of ferroalloy and aluminum alloy, the processing of titanium alloy is much more difficult.Imagine it is stainless steel, but the chip is relatively stronger and more tough, when the feed, return knife more likely to cause the tool to break.The PVD coated ic908-ic907-ic1008 is recommended for high speed cutting to avoid tool overheating.
Professional machining tools
The good news from ISCAR is that it has developed a range of small blades for use in titanium alloy workpieces.The common characteristic of these tools is that they are very sharp, polished or ground to the front with a high surface finish to prevent the formation of debris.In fact, most of the alloy grades are IC908, which is a proven grade used in titanium alloy processing in the aerospace industry.ISCAR has a series of micro tools for machining titanium alloys, including: very sharp cutting edges, special chip grooves, end mills with polished surfaces;Solid carbide drill with minimum diameter of 0.8mm and p-shaped geometry;Solid carbide reamer, minimum diameter 1mm, s-shaped geometry;Four kinds of sharp blades with WF and MD chip grooves;JETCUT cutter - specializes in titanium alloy cutting.
SCAR deeply analyzed the characteristics of implants in the medical device industry in order to improve the processability of these very critical components. Therefore, special tools, blades, and coiling grooves were also designed and manufactured to process titanium alloy Ti6Al4V and obtain high precision tolerances required in this particular field.In conjunction with manufacturers of such components using their existing production facilities, ISCAR also provides tailor-made tools for different applications.
Solid carbide end mills with sharp cutting edges developed by ISCAR can be used to process concave parts without burr.These end mills can achieve a maximum margin of 0.01mm polishing milling in semi-finishing and finishing.ISCAR has also developed tools for processing both titanium alloys and stainless steel -- PVD coatings based on ultrafine matrix particles -- to achieve high cutting speeds and high feed speeds.ISCAR's new solid carbide drill has a minimum diameter of 0.8mm, sharp cutting edge, p-shaped geometry, alloy IC908.ISCAR's new solid carbide reamer, minimum diameter 1mm, sharp cutting edge, s-shaped geometry, alloy number IC908.
ISCAR's research and development section found that turning in the medical device industry required improvements in both the blade number and the roll groove.In order to meet the needs of users, ISCAR has developed high quality abrasive blades such as VCET, DCET, CCET and WF.ISCAR's advanced manufacturing technology ensures that these improved blades have polished coiling grooves to achieve excellent surface quality for semi-finish and finish.In some special applications, ISCAR can provide a VCGT blade with an MD roll chip groove for high surface quality.
ISCAR jet-cut series, blade width 3mm and 4mm, alloy IC908, high surface quality, long tool life.Based on ISCAR's belief that there is no limit to upgrading, ISCAR has developed the HP high pressure cooling system tool based on the tang-grip series.
ISCAR is focused on providing innovative solutions that enable users to demonstrate competitive advantage in the industry by using innovative tools to obtain high quality artifacts and reduce processing time.
Clever use of professional tools
Titanium alloy has the characteristics of work hardening.The cutting Angle is large, the chip is thin, and a relatively small contact area is formed on the tool.In addition, the high cutting force in the machining process, combined with the friction when the chip movement, will lead to the tool local cutting heat is too high.However, the thermal conductivity of titanium alloy is poor, so the cutting heat can not be transferred out quickly.Therefore, a great deal of cutting heat is concentrated on the cutting edge and tool surface.High cutting force, cutting heat will combine to cause the crescents, and cause the rapid failure of the tool.
The relatively low elastic modulus makes titanium alloy more elastic than steel.Therefore, should avoid cutting force is too large, in order to ensure that the rebound of the workpiece is small.Thin-walled parts tend to deform under tool pressure, causing tremors, friction and even tolerance problems.The key to solve the problem is to ensure the rigidity of the whole system, using a sharp cutting edge, the correct geometry of the tool is very necessary.In addition, titanium alloy has the tendency of chemical reaction with cutting tool alloying at high temperature, and its chip has the tendency of welding to the cutting tool surface.
To sum up, in the face of all the opportunities and challenges of processing small parts, the use of cutting edge tools, can greatly improve the user's competitive edge.