Complex Micro-Manufacturing with Multi-Tasking Machining

For producing small parts used in micro-mechanics, aerospace, med-tech or luxury goods applications, the Bumotec s191FTLR 7-axis turn-mill from Starrag USA Inc. (Hebron, KY) manufactures complex parts in a single setup, whatever raw materials are used. It can cost-effectively achieve the high level of precision and repeatability required for producing medical implants by combining grinding, milling, turning, drilling and polishing processes without interruption. The requirement to manufacture complex micro-size parts is in high demand, particularly hard materials used in the med-tech industry. One such example is the “femoral head” made out of chrome cobalt. Starting with a plain bar and finishing the femoral head in a single setup, the Bumotec s191FTLR performs six-sided machining – including grinding of the spheric shape (sphericity 2.5 μm) with high precision and accurate polishing (roughness RA 0.05) without interruption of the cycle, which takes about 12 minutes to complete.

Once the bar is loaded, the machine takes very little supervision to produce a precise femoral head by using dynamic correction capabilities and Renishaw contactless part probing techniques. With a uniquely designed full-size sub-spindle and Fanuc linear motor drive, the Bumotec s-191FTLR can precisely turn, mill, grind, surface finish and five-axis machine medical femoral heads from high-mix small batches to large volume serial production. The advantage of machining such complex shapes in a single cycle is realized through quick change over, higher productivity, lower cycle times, less floor space and the sharp reduction in part handling. These benefits yield a more accurate and reproducible part at a lower manufacturing cost than traditional machining methods that require numerous setups on various machine tools.

Starrag USA Inc., Skyport Business Park, 3279 Progress Drive, Hebron, KY 41048, 859-534-5201, ussales@starrag.com, www.starrag.com.