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What are the difficulties in the processing of medical device parts?
In recent years, the medical device industry has shown a dynamic growth trend, and difficult materials, complex workpiece shapes and frequent small batch production have put forward higher requirements for the processing of medical devices. So what are the problems when processing medical device parts, and the following explains the new problems faced by the processing of medical parts?
The medical device industry has put forward new requirements for professional precision tools
Difficult materials, complex workpiece shapes and frequent small batch production place high demands on tools for machining specialist medical devices. Transplant products and prostheses, for example, play an important role in successful surgical procedures to help surgeons achieve optimal medical outcomes. The tools used to process medical devices largely determine the quality of medical devices.
First, the processing materials of medical parts are difficult to process:
90% of medical device implant parts are made of Ti6Al-4V titanium alloy, which is due to lightweight, high strength and high biocompatibility, and titanium alloy 6AL-4V has become the most commonly used material for medical implantable devices. Titanium alloy 6AL-4V is commonly used in the production of hip joints, bone screws, knee joints, bone plates, dental implants, and spinal connecting elements. Titanium alloys have work-hardening properties. The machining process has a large shear angle, produces thin chips, and creates a relatively small contact area on the tool. In addition, the high cutting force during machining, combined with the friction force during chip flow, will combine to cause the local cutting heat of the tool to be too high. The poor thermal conductivity of titanium alloy makes the cutting heat not quickly conduction. As a result, a large amount of cutting heat is concentrated on the cutting edge and tool surface. High cutting force and cutting heat will comprehensively cause the generation of crescent depressions and cause rapid failure of the tool.
Reliable and compact machine tool fixture
Medical device processing equipment needs to be able to process small and complex parts made of difficult-to-machine materials (such as titanium alloys or stainless steel) with high precision requirements, such as processing bone and joint replacement parts. Due to the poor cutting properties of the material being machined, the stock is usually bar stock – which means that a large amount of metal needs to be removed. As a result, part of the part is cast into a shape close to the finished product, but this also adds to the hassle – the need to manufacture complex and expensive fixtures. Another factor that adds to the complexity of machining is the narrow tolerance range.
Medical device parts have high requirements for workpiece materials, processing accuracy, surface finish, etc., which requires high reliability of the processing system. Therefore, it also puts forward extremely high requirements for machine tools, fixtures, tools, CAM software, etc. Workpieces are typically machined on state-of-the-art medical device processing equipment such as Swiss automatic lathes, multi-spindle machines and rotary tables. Most of these machines are characterized by their very small size and very compact size.
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