Analysis of the demand for processing technology in the development of artificial joints

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The artificial joint replacement technology has experienced nearly 100 years of history from the early exploration to the current relatively mature stage. Through the continuous efforts of the medical and engineering manufacturing industries, whether in design concepts, medical materials, manufacturing technology and testing technology. Great progress has been made in the field, and countless patients have benefited from it.

Under the promotion of clinical statistical data and the progress of scientific analysis, especially in the manufacturing process, a large number of modern technologies such as reverse modeling, numerical control processing, rapid prototyping, high-energy beam (laser and electron beam) processing, etc., make many of the original The realization of the design concept becomes possible, and thus the artificial joint technology is facing a new wave of changes and progress. Along with these changes and advancements, new demands and expectations for manufacturing technology have also arisen.

(1) Although the various design concepts in the development of artificial joints in recent years have emerged in an endless stream, one factor is relatively stable and the change is gentle, which is the material used. Artificial joints are medical devices implanted in the human body, and the life expectancy is usually 10 to 20 years or even longer, so people are very cautious in the choice of artificial joint manufacturing materials. After years of use screening and limited variety of products recognized by the industry, the most commonly used materials include titanium and titanium alloys, cobalt alloys, and ultra-high molecular weight polyethylene (bioceramics and animal-derived materials are less used for machining, This article does not cover), the common feature of the above materials is that the machining is more difficult. For example, the current maximum amount of titanium and titanium alloys have poor mechanical cutting performance, mainly due to low thermal conductivity. A large amount of cutting heat accumulates at the cutting edge of the tool at higher speeds, which exacerbates tool wear; titanium metal is chemically active and high temperature There is a risk of causing fire; the surface work hardening phenomenon is serious, affecting the surface roughness and dimensional accuracy of the product; in addition, the continuous winding of the chips is also one of the most headaches; and the hot hardness of the cobalt alloy is recognized in the industry. problem. Although the hardness and strength of ultra-high molecular weight polyethylene are far less than the above-mentioned metal materials, the high viscosity causes the chip breaking difficulty, and the temperature rise of the cutting region causes local softening or even melting, which seriously affects the surface roughness.

All these kinds of inconvenience and troubles have been brought to the processing and production of enterprises. Applicable tools have always been one of the goals that artificial joint companies are striving for. We hope that the tools specially designed for the above materials have satisfactory hardness, heat resistance, low wear, and good guiding and chip breaking functions. Dealing with the entanglement of the chips has always been a headache, and it is often necessary to interrupt the processing and stop the safety door to eliminate the problem. If the machine tool builder, software developer and tool manufacturer can work together to provide a solution, such as an automatic device that assists in the handling of chips on the machine, a corresponding program in the operating system, and a tool with good guidance or chip breaking function, It is possible to greatly alleviate the energy and working hours of the user in this work.

(2) With the improvement of economic conditions and the increasing requirements of the medical profession for the accuracy of surgery, the individual differences of different patients have higher and higher expectations and expectations for personalized and quasi-personalized products, in order to comply with this trend, artificial The design of joint products has also begun to focus on and try to move closer to personalized design and rapid manufacturing. However, due to various constraints such as manufacturing methods, processing cycles, manufacturing costs, and security verification, universal personalization cannot be fully satisfied. As an alternative, multi-species and multi-spec products have also been introduced to the market because they can effectively approach and meet the anatomical requirements of individual patient joints (see Figures 1 and 2).

A side effect of multi-spec design is that when the total production volume is constant for a certain period of time, the output of each specification product will be dispersed and reduced, the process will be changed frequently, and the work of replacing the adjustment tool will be replaced. The amount and time it takes up is greatly increased. For a machine tool that requires frequent replacement of products, the speed advantage brought by the rapid performance of the machine, such as rapid moving speed and rapid tool change, is completely replaced by a large amount of man-hours for tooling, tool change, and program debugging. Submerged.

Taking the general-purpose CNC lathes and slitting lathes commonly used by artificial joint manufacturers as an example, although there are usually positioning devices between the holder and the holder, the accuracy is not enough, and different types of different grades of the knife are replaced in the product change. After the handle, it is often impossible to quickly return to the initial state when the product was last processed. If an accurate positioning mechanism can be set between the tool holder and the tool holder, it is possible to fix the tool parameters in the machining program. Only need to perform the external tool calibration in advance to confirm the between the tool and the tool holder. Install the positioning parameter accuracy. When the tool holder is quickly loaded on the tool holder, the original program can be directly called to enter the test cutting. After inspection and appropriate tool compensation, it can be turned to normal processing. The realization of this idea will bring great convenience to the production mode of small batches and multiple varieties.

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