Defend life safety with "precision tools"
Walter: Challenge the processing of difficult materials
Tolerances in the micrometer range are common in the medical industry, and choosing the right tool requires keen insight and extensive experience. On the one hand, even drilling holes requires the use of lubricants to reduce friction, reliably dissipating heat and handling fine iron filings at the edges; on the other hand, the use of sharp and smooth running in the production of cutting-edge medical devices (without burrs) Cutting tools for high quality surfaces. Common cutting tools are high speed steel drill bits or solid carbide drill bits. The Walter Titex drill bit from the Walter Group of Germany processes hard-to-machine materials such as titanium, stainless steel, precious metals and even composite materials. The standard size of the machining center hole is 0.05~46mm, and the internal cooling type The drill can be up to 0.75mm in diameter. Milling and Drilling - Dental Restoration As a standard, Walter Prototyp's Protostar series of solid carbide tools range in diameter from 0.3 to 20 mm. The Pratt production plant is located in Germany and is a well-known supplier to the medical industry. Its taps and thread milling cutters are mainly used for the processing of titanium alloys, such as bone screws or joints. Thread milling cutters with a diameter of 1.6 mm can also be used to produce dental restoration products.
Protostar Ti40 hard end mill
Manufacturing tool for transplant products
Although Walter has been involved in the medical industry for a long time, the classic application of the product focuses on small-sized medical devices (such as bone screws and implants) that are extremely demanding in precision. The indexable carbide inserts WSM10, WSM20 and WSM30 are mainly used in multi-axis machines . The Tiger Blade's Tiger-tec® coating and microcrystalline substrate provide maximum stability to the process. The heat-resistant Al2O3 coating provides maximum resistance to high temperature hardness and wear. In addition, the sharp cutting edge ensures burr-free product. And no built-up edge. Since titanium is one of the most frequently processed materials in the medical industry, the new geometries NFT, NMT and NRT are used to process titanium. NFT is used for finishing, NMT for medium precision machining and NRT for roughing. These inserts can be easily combined with a tooling system such as the Walter Toolbar XLDE for user operation.
Customized compound tool solutions save time and money
If a company wants to stand on the competitive international stage, it must produce high-quality products at low cost. For graft products (generally made of high-alloy steel, titanium or titanium alloys), special materials and complex workpiece geometries pose significant challenges to product accuracy.
For some machining, three standard tools may have been used before, but now only one composite tool is needed to replace the previous three processes with one operation, saving time and cost. For example, machining 1,500 workpieces, saving 2 minutes per workpiece, can save 50 hours of machine work. The disadvantage of this composite tooling solution is that it is not reflected in the generic tool sample. Walter's "CATexpress" custom non-standard tool service is different from the regular non-standard service, and its delivery time can be reduced from the previous 6-8 weeks to 14 days. The service is based on a special software program. When the user connects to the Internet and enters all information (such as application information or machine type), the system outputs an order record containing the required parameters. After receiving the order, the company can start producing the required non-standard tools in the shortest time.
Sandvik Coromant: perfect medical small parts processing
Some cutting tool concepts make machining of small parts in the medical industry more efficient and significantly increase productivity. In particular, the slitting machine for small parts has been further developed, and the cutting tools have been continuously introduced, thus providing the high performance required to maximize machine utilization. Some cutting tool areas have been upgraded to new levels of performance – threaded cyclone milling and turning with high pressure cooling (HPC) are two prominent examples.
High precision threaded cyclone milling
Thread whirl milling
This is often the case with suppliers in the medical industry, where the processing of slender screws (such as bone screws) for high-volume production of high-performance metal materials is increasing, and thread-wound milling is an established method of processing. The inherent stability of this process makes it ideal for high-volume production and processing of demanding metal materials. However, cyclone milling can use a more robust cutting edge, which opens up more possibilities for introducing new tool materials with higher wear resistance.
The benefit is that the tool life is quite long, which means shorter machine downtime during production. In addition, the edge toughness of the cutting edge is improved, making the cutting edge sharper and safer for cutting. The rational use of these technological advancements in other processing areas and the development of special indexable inserts and tools for small part cyclone milling consolidate the economic advantages of manufacturing medical parts.
The ever-increasing development of blade technology provides more room for improved cutting edges, allowing for the full benefits of threaded cyclone milling. For example, coated carbide inserts result in longer and more predictable tool life and the ability to apply higher cutting speeds. This results in higher part yields and consistent tolerances and surface finish. New blade materials (such as those with PVD/TiAlN coatings) have a unique thin coating that provides excellent adhesion to the blade substrate. This material has proven to be very advantageous for the sharp cutting edges required for thread-wound milling of various workpiece materials, such as the metal materials used for bone screws.
For thread-wound milling, operational safety and tool clamping are also critical to ensure higher processability. Tool accuracy determines blade positioning, the quality of the blade grinding, and the convenience and reliability of each time the blade is properly positioned. The newly developed blade clamping concept for threaded cyclone cutters improves the positioning accuracy and machining safety of the cutting edge and makes tool change on the machine tool easier and faster.
At present, threaded cyclone milling cutters should include specially developed precision grinding inserts and semi-finished products, and should be compatible with most types and configurations of sliding tool holder spindles. Despite the well-established process in mass production, new processing techniques are required to meet higher production and new part requirements, such as the more advanced tool ring concept in threaded cyclone milling.
High pressure cooling system
The use of high pressure cooling systems to replace conventional cutting zone coolants has many processing advantages. The introduction of this auxiliary cutting method can be carried out using standard tools as well as internal cooling. In the processing of materials with strict chip control requirements (such as superalloys and mild steel), the biggest advantage of this solution is improved machining performance and chip removal.
New machining concepts are now available for small part machining, allowing high pressure coolant to be injected directly into the cutting zone. This type of solution combines precise orientation of coolant spray and tool holder clamping for simple and safe features. This opens up a whole new perspective on the processing of demanding materials, especially on slitting machines where small sets of tools are located in very narrow spaces, and tool change and clamping are difficult and time consuming. With a tool positioning and locking function and a machine with a coolant connector, the new tool clamping system can simultaneously improve machining and tool change.
Turning tools with high pressure cooling (HPC) function typically have three nozzles that precisely deliver the coolant jet to the appropriate position on the blade. The coolant affects the distribution of heat generated in the cutting zone, the amount of tool wear, the actual form of the chip, and the degree of bonding of the workpiece material attached to the cutting edge. The coolant jet is effectively shortened by the so-called "hydraulic wedge" formed between the chip and the rake face of the insert. Achieving good chip control in the machine helps ensure safe unattended production as well as tolerances and surface finish levels of machined parts and thereby increase productivity.
On machine tools suitable for small part machining, the application of a high pressure cooling system enables quick and easy tool change. This is achieved by clamping and loosening the shank with only one Screw and a Spring-loaded wedge for fixing the shank in the tool holder. Accurate and safe cutting edge positioning is achieved when the tool holder is installed and replaced. In combination with the internal cooling of the shank and the simple and safe coolant connection between the shank and the seat, the long chip material that is difficult to machine without trouble-making is a common cutting method for processing small parts in the medical industry.
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