Precision Redefined: Cutting-Edge Solutions for Future Medical Machining

The proposed article introduces innovative solutions for machining parts in the medical industry, emphasizing the ongoing importance of machining in medical part production. As a substantial consumer of cutting tools, the medical sector poses unique challenges and demands specific features from a tool manufacturer’s perspective. The article explores the intricacies of machining various medical components, focusing on the forefront role of tools in orthopedic component machining and identifying emerging cutting tool trends.

Cutting tools in this context are specialized for machining small-sized and miniature parts within confined spaces, falling under main application groups ISO S and ISO M. They are designed to meet high accuracy and surface finish requirements. Small tool diameters in rotating tools lead to significantly increased rotary velocities, demanding balance and dynamic strength margin for effective performance under high speeds.

The influence of cutting tool design engineers on new tool developments is paramount, and the latest products from ISCAR contribute to understanding these factors. Specifically, the PICCOCUT line of miniature tools is highlighted, featuring a coolant-through-tool mechanism with pinpointed emulsion directed at the cutting edge, enhancing efficiency. The article also discusses double-sided holders with internal coolant channels and a user-friendly clamping mechanism, ensuring high stiffness clamping for improved cutting performance.

For machining orthopedic medical components, ISCAR introduces turning tools with ISO standard inserts for Swiss-type and CNC lathes, incorporating the SAFE-T-LOCK clamping mechanism for precise and extremely rigid insert mounting. The availability of a high-pressure cooling option enhances turning under challenging conditions, improving productivity and prolonging tool life.

Recognizing the cost-saving potential of narrow widths of cut, ISCAR presents a new range of compact tools with SELF-GRIP inserts, facilitating slim cuts and minimizing material waste. These tools, intended for Swiss-type machines, are suitable for machining narrow external grooves.

Small-sized solid carbide drills, commonly used for drilling orthopedic components, face challenges in miniaturization. ISCAR’s recent reduction in the lower limit of the diameter range for SUMOCHAM drills with interchangeable carbide heads to 4.5 mm represents a significant advancement in cost-efficient assembled drills for the medical industry.

The article discusses the theoretical aspects of ball-nose milling cutters for fine milling complex-shaped parts, highlighting the challenges of cycle time increase due to diminishing step size. It introduces barrel-shaped mills or “segment mills” as an effective solution, especially in five-axis profile machining of formed orthopedic components. ISCAR’s addition of high precision “cutting barrels” to its product range is aimed at semi-finishing and finishing titanium, superalloys, and austenitic stainless steel, common materials in the medical industry. Barrel-shaped mills provide a smoother surface, reduce the number of cuts, and decrease process time.

Small-size rotary tools for cutting operations, including milling, drilling, engraving, deburring, and others, demand substantial rotating velocity, especially in high-speed machining (HSM) strategies. ISCAR addresses this with its new high-pressure coolant-driven MICRO 90 spindles, enabling rotating velocities in the range of 35,000-53,000 rpm while the main machine spindle remains idle.

In conclusion, the rapidly growing medical industry, with its focus on new engineering materials and technologies, relies on innovative machining solutions provided by tool manufacturers. The article emphasizes that these evolving trends challenge the medical industry to seek solutions from tool manufacturers, who remain focused on changing industry trends to offer ultimate solutions for machining complex medical components.

Original source MMSonline