t h i n k p a r t s T h i n k T o r n o s Medical Proven solutions in the medical sector for over twenty years.

Transcription

1 t h i n k p a r t s T h i n k T o r n o s Proven solutions in the medical sector for over twenty years.

2 The challenge of the medical industry Dialogue which has been set up between companies which design and produce products in Medtech (e.g. implants for orthopedics, trauma, spine, dentistry, tooling, etc.) and Tornos enables us to have a better appreciation of our clients needs. In this way, we are able to define, develop and propose optimum machine equipment, solutions and machining processes. Our end objective is to provide optimum manufacturing solutions which meet our clients expectations, based around a productivity platform defined by market segmentation. A knowledge of the market and its needs enable us to develop machines which are perfectly in tune with the different sub-sections of this market, which are : traumatology orthopedics area of the spine tooling dentistry

3 Is our challenge Doctors Research Tornos Manufacturers Tornos have been pioneers in this sector for over twenty years. By virtue of our developments and practical expertise in the medical sector, we are in a position to propose different machining options for parts up to 32 mm, on our range of singlespindle and multispindle turning machines. Competition means that Medtech manufacturers and subcontractors are under ever-increasingpressure to reduce prices. This must not affect zero defects which must be enforced. Dependable and highly productive production methods are paramount. A challenge taken up by Tornos with its machining solutions.

4 our technology at your service for all types of parts. You make highly demanding products, Tornos can offer you proven solutions within a very wide range of parts. We are at your disposal to find a tailor-made solution for your manufacturing process. Hundreds of Tornos turning machines delivered in the Medtech sector produce parts in a range of dimensions on site at our customers locations. These are machined from a bar of material which can range from 1 mm to 32 mm in diameter. As far as the product is concerned, we offer expert advice to guarantee you the best choice in terms of kinematics, machining, equipment and tooling performances. By virtue of our expertise we have acquired in materials specific to this field, (e.g. stainless steel for implants, titanium, peek, biodegradable materials, etc.), we offer the best tools and machining conditions to optimise cycle times and increase productivity. The Medtech sector has been enjoying a period of continuous business growth for several years. Technology is changing very quickly, R&D departments from leaders in the Medtech market and other OEM are bringing new products onto the market at an ever-increasing pace. New materials and alloys, some of which prove very challenging to work with, are appearing on the market. Manufacturing and machining some parts, or even certain groups of parts, can be a real challenge. By virtue of their experience and expertise which have been built up over more than fifteen years working in this sector, Tornos develops products which meet the needs of the market, highperformance equipment in terms of machining and reliability, new software developments, as well as machine features and other programming options in order to anticipate the needs of the market and meet their customers expectations. In the different sub-sections of Medtech (trauma, spine, orthopaedics, dentistry, tooling, etc.), requirements are not always the same. The optimum machining method for this type of part must therefore be selected. Tornos is the world s only manufacturer to offer machining solutions dedicated to Medtech on single- and multispindle turning machines for bar diameters up to 32 mm (small and medium-sized). Peripherals Product ranges, their technical specifications and their performances are dedicated to machining parts of mid- to high-level complexity : Sliding headstock single-spindle turning Services / Support Advice machines : DECO Sigma and DECO product range "a". Multispindle fixed headstock turning machines : MultiDeco or MultiAlpha range (6 or 8 spindles). Customised machining Turn Key By virtue of the DECO concept, productivity remains the number one USP at Tornos, who are aiming to consolidate their position on the international automatic turning machine manufacturers market.

5 A TRIED AND TESTED CONCEPT Complete command of machining processes, practical expertise built up over many years and close collaboration with highly competent partners in the Medtech sector (tooling, materials, lubricants, peripheral equipment, etc.) enable us to position ourselves as "solutions provider" on this demanding market. The Medtech market and sub-sections. As far as dedicated solutions are concerned, it s important to know how to design and adapt products to the type and dimensions of the parts to be machined. The concept of product families and lines that we manufacture is a benefit when it comes to use by our customer base. Whether it s a question of kinematics or programming tools, we always strive to standardise the use, programming and settings of different products. Every machining operation, whether whirling external and internal threads, tangential thread milling, gear hobbing, drilling deep bores at high pressure of up to 350 bar, stamping, shaping using high-speed milling (e.g. Torx forming), is possible on virtually all the products we offer (single-spindle and multispindle). These operations are also possible during a counter operation (second spindle), which very often means that machining times for each operation at the bar and in counter operation are evenly distributed and well-balanced which in turn improves productivity. Machining times are shortened considerably, despite the extreme complexity of some parts. We also base our everyday operations on this idea of real productivity in order to remain one step ahead of the competition and offer solutions which are perfectly suited to each requirement. A tried and tested concept Every one of your developments undergoes a tough validation process at every stage of the manufacturing and industrialisation process, whatever the level of integration envisaged for the final product. This process involves taking several different parameters and their implications into account.

6 A solution for every type of part DECO 10a Maxillofacial screws Humeral locking screws Schanz screws Guide wires Dental implants Dental abutments Caps / screws Drill / reamers Example : maxillofacial screws, micro screws and dental implants Sleeves / connectors DECO 13a Bone screws Cannulated / corticalis screws Corticalis / malleolar screws Humeral locking screws Locking screws Trocar Connecting rods Drill sleeves Example : trauma and orthopaedic screws with complex dental implants and abutments Distraction / compression rods Dental implants Angled abutments Drill / reamers DECO 20a / 26a Cannulated screws Nails Lag / hip screws Mono / poly axial screws Spine hooks Poly axial heads Connecting rods Tooling Example : trauma orthopaedic and spine (mono and poly axial) screws, nails, hip screws. Nuts

7 for machining your parts without secondary operation Sigma 8 Dental abutments Caps / screws Sleeves / connectors Example : screws for implants, covers, simple abutments Sigma 20 Bone screws Locking screws Corticalis screws Connecting rods Nails Nuts Tooling Example : screws for implants, covers, simple abutments MultiAlpha 8x20 Polyaxial heads (spine) Bone screws Implants Example : Poly axial head for spine, orthopaedic nut, screw

8 SOLUTION PROVIDER Oil and air filters High pressure pumps Machining and processing Burring Cleaning Part-feeders Pallettising Manipulating Chip conveyors Measuring µ Bar-feeders Every day we work on making sure you can reach your manufacturing, productivity and machined component quality goals. Pressure to lower prices, ever-tighter deadlines, small production series and numerous set ups are the kind of challenge you face every day to stay ahead of the competition. Tornos can offer you the right solutions to make this happen. Machining without secondary operation We develop tailor-made kinematic machines which mean you can increase your productivity. We can offer you tooling which is perfectly suited to your product and materials. We take care of the whole spectrum : machine-tools-cutting liquids-materials to optimise machining conditions. We reduce set up times with rapid programmable changeover tool systems. Turning Thread-whirling process Milling Boring Stamping Cannulated screw (trauma) in titanium 380 sec.

9 PRODUCTS PERFECTLY SUITED TO YOUR REQUIREMENTS T12 T12 T12 T15 T15 T15 T21 T21 T21 T42 T42 T42 T31 T31 T31 T41 T41 T41 T32 T32 T32 T33 T33 T33 T13 T13 T13 T24 T24 T24 T53 T53 T53 T15 T15 T15 T23 T23 T23 T14 T14 T14 T51 T51 T51 T42 T42 T42 T43 T43 T43 Products perfectly suited to your requirements We are experts in complex machining processes. We develop software functions for machining complex shapes. We design equipment which is specific to your own production requirements. We develop specific cutting tools and other tooling in close collaboration with partners skilled in the field. We can offer peripheral equipment perfectly suited to your needs (safety, handling, measuring, operator and environmental protection). Optimum productivity We develop new machining processes on multispindle turning machines to reach an extremely high level of productivity. For parts in the Medtech sector, we also adapt multispindle products to be able to run specific operations (e.g. thread-whirling process, high pressure drilling, internal and external micro-milling). We adapt peripheral equipment (e.g. handling, measuring, swarf processing) as well as all other general client parameters which are key to productivity. Z4 S1 S5 X4 S5 Y4 Z1 X2 S2 X1 S4 Y2 Z3 S3 S6 Y1 X3 Dental abutment (for implant) in titanium

10 ONE PROGRAMMING SOFTWARE FOR ALL PRODUCTS One of the many benefits offered by Tornos is the development and manufacturing of single-spindle and multispindle products, all programmed using the same TB-DECO software. This technological expertise means that customers can benefit from a single and straightforward programming of their machine park, can reduce the set up time of their machines and whose employees are able to work on different types of products. The TB-DECO software is run on a user-friendly Windows environment. There is the option of setting up interfaces with internationally recognised CAM systems. TB-DECO is a tool which benefits from the power and progress in I.T. while continuing to use standard ISO programming language which is familiar to operators. TB-DECO, a software which is continuously evolving through updates which put all the latest software developments at the customer s disposal. TB-DECO, the one and only system which manages all the axes of the machine and the different tool systems simultaneously. Graphic machining simulation and assistant graphic showing programming programmed contour. 10

11 examples of parts 11

12 medical applications Maxillofacial, orthopaedics, trauma, hip screws Steel 316 L 125 secs. Steel 316 L 148 secs. 320 secs. 145 secs. 206 secs. Steel 316 L Steel 316 L 306 secs. Steel 316 L 254 secs. Steel 316 L 375 secs. 12

13 medical applications Mono and poly axial spine screws Steel 316 L Steel / titanium 13

14 medical applications Long parts Steel 316 L 267 secs. 720 secs. Steel 316 L 220 secs. Steel 316 L 295 secs. 14

15 medical applications Implants / dental components 110 secs. Stainless steel 316 L 140 secs. Stainless steel 316 L 120 secs. 130 secs. Stainless steel 316 L 145 secs. 105 secs. Stainless steel 316 L 140 secs. Stainless steel 316 L 55 secs. 360 secs. 280 secs. Stainless steel 316 L 80 secs. 186 secs. 250 secs. 95 secs. 125 secs. 115 secs. 98 secs. 15

16 Machining technology External thread-whirling process (main operations and counter operations) Centering device Sharpening device Blade holder head Circular blades The machining of threads for medical and dental implants requires an outstanding level of precision, respect of the shape of the thread and the finish, as well as burr-free machining. Several factors can influence the end quality of the thread. A pioneer in this sector, Tornos is the first company to have produced and controlled the thread-whirling process on a sliding head turning machine. Our experience allows us to control the design of cutting tools which are specific to this operation. For the customer, the benefit comes in the form of having one single partner for the machining process and technical support. Why the thread-whirling process? Materials which prove difficult to machine, such as titanium and stainless steel for implants, require cutting conditions which are perfect and adapted to the needs. The shapes of threads used for implants are generally specific to this sector and must be totally burr-free. Once it has been machined, the thread needs to be both extremely sharp and tough enough to allow for a perfect implantation into the bone material and which is without risk to the patient. The thread-whirling process uses cutting speeds which are greater than traditional threading operations. When cutting stops in the material, the very high rotational speeds mean that the swarf and its shape are kept under control. This way, swarf removal is straightforward. High pressure lubrication is used to direct the flow of swarf. 16

17 Machining technology Internal thread-whirling process (main operations and counter operations) External thread-whirling processin counter operation Internal thread-whirling tool Tool Ø 1 mm x s c z Principle diagram for internal thread-whirling process Spindle r p m Benefits of the process During the thread-whirling process, the external thread is does not require a prior turning operation for the majority of parts (enhanced productivity and improved rigidity of bar). Low cutting forces due to different cutting edges and tool rotation speeds. Superior general quality of finish compared to standard threading processes. Threading in a single cut. Threads go in and come out "whole", no tapered threads. Perfect swarf control (fine particles) by virtue of adapted cutting speed and cutting lubrication on unit (pressure 20 bar). Tool lifetime is extended and tools can be Depth is controlled during internal threadwhirling process in blind bores. Thread-whirling tools adjusted with tool holder head inclined depending on angle of thread (up to 24 degrees). Length of thread-whirling process up to 200 mm depending on type turning machine. No burrs outside or inside threads. External thread-whirling process at the bar and in counter operation in 'masked time' mode (Deco 20a/26a). Internal thread-whirling at the bar and in counter operation in 'masked time' mode. resharpened (regular profiled blades / approx. 40 possible resharpenings) Machining technology with regular-profiled blades or disposable inserts. Cutting tools are pre-set before entering machine and rapid assembly / disassembly of tool holder head. Thread size is controlled by turning machine s digital axes (diameter / length / tool centering). 17

18 Machining technology Boring / drilling deep bores at high pressure 120 / 350 bar Using a high pressure cutting liquid (up to 350 bar) for boring deep bores is often essential to guarantee cost-effective and productive machining of different components in the Medtech sector (chamfered screws, hip screws, tooling, etc.). Many implants on the market require transverse bores. In general, the ratio between the drilling diameter and the length to be machined is high (drilling length up to x the diameter), depending on shape of part. Materials to be machined, in particular stainless steels, titanium and other steel alloys require machines, tool systems and high-performance peripheral equipment which offer the user different options depending on requirements. High-pressure deep drilling devices (120 and 350 bar) can be adapted to suit the majority of our products. Our turning machines are equipped with a standard interface and specific tool holder per type to ensure they can be adapted to the product very quickly and simply. Our kinematics are specially adapted to the fitting of these options, taking into consideration the space available for the different tool shapes (no risk of collision). Generally, the kinematics of DECO turning machines also mean that main operations (bar) or counter operations can be carried out for machining in 'masked time' mode. In principle, all Tornos single-spindle and multispindle turning machines can be adapted. 18

19 Machining technology Boring / drilling deep bores at high pressure 120 / 350 bar Technical specifications 120 bar 350 bar Oil tray capacity litres Motorised pump flow cm Max power kw 4 4 Number of exits (valve actuation) 4 4 Programming of machining pressure by the part program M620-M623 M620-M623 Exit pressure min-max adjustable bar Flow min-max l / min Min boring diameter mm Max boring diameter mm 12 3 Typical examples of customer applications 120 bar 350 bar Material titanium grade VI titanium grade VI Boring diameter mm Machining depth without de-coring mm (52 x diameter) (62 x diameter) Benefits Part is machined from start to finish on the turning machine in a single fixture setting. Improved productivity (total cycle time) No burrs Straight plane (very little deviation of drill bit) Deco 20 / 26a high-pressure rotating drilling spindle up to 120 bar (higher cutting speed and eccentric drilling possible). 19

20 Machining technology Machining Torx shapes and other specific high-speed milling applications applications occasionally require milling / drilling with extremely small-sized tools. High-speed spindles are also key to achieving optimum cutting parameters and the required finishes. High-frequence spindles enable rotation speeds of up to rpm to be reached. Very small tool dimensions often involve several machining passes for roughing and finishing work. Torx shapes require such machining to ensure precision and finish quality. These operations can be carried out on the turning machines both as main operation and as counter operation in 'masked time' mode. The axes can be interpolated with one another and synchronised with the C axes on the spindles, thus enabling each special shape to be turned accurately. The same high-frequence spindles are used for internal thread-whirling operations and other end / transverse operations which require high cutting speeds. Benefits Perfect for use with small-sized tools. Can be adapted to suit all products in main and counter operation. Suitable for confined spaces. Straightforward rotational speed setting with potentiometer. Cutting speed adapted for increased productivity. 20

21 Machining TechnOlOgy Machining specific shapes with the stamping process for parts used in orthopaedics, trauma, spine, tooling and parts such as dental implants, stamping operations are often required. We are experts in this process on Tornos turning machines by a virtue of our wide-ranging experience in customer applications in this sector as well as an in-depth knowledge of the necessary tooling for such an operation which can require considerable cutting force. spindles (main and counter spindles) must be able to resist the axial cutting forces of this process. different solutions are available including fixed stamp, rotational stamp and driven stamp. various specific supports and stamp holders are available depending on customer requirement. Benefits Machining without secondary operation. stamping operation can be positioned at an angle with other references on the workpiece. can use other tools for burring after stamping operation. 1

22 Machining technology Milling and multi-axis interpolations for machining of complex shapes Some components, especially for spine, nails and dental implants applications, require specific equipment to produce complex forms, usually by milling. Tornos is continually developing new options which are suited to the needs of the customer. Alongside this, we are also developing customer specific macros to make the programming of complex contours more straightforward. These operations can take place either at the bar-turning or counter operation stage, usually in 'masked time'. Simultaneous 3 or even 4-axis interpolations are carried out to render these specific machining operations possible, always with the aim of finishing the part without the need for a secondary operation. Depending on quality parameters, machined shapes in materials which are difficult to work in (e.g. titanium and stainless steels for implants) often require rough finishing before being finished in successive operational stages. The TB-DECO software s simple programming and the many options available make different operations considerably more straightforward. Benefits Machining highly complex parts without secondary operation. Straightforward programming of shapes with specific macros (automatic calculations of axis movements and incremental program steps). Counter operations generally carried out in 'masked time' mode. Milling units are mechanically set for angular tool positioning depending on part. 22

23 Peripherals Wide range of peripherals available depending on market needs Tool pre-set on Tornos pre-setting equipment or adapted to suit customer s own pre-setting equipment The pre-setting equipment is an essential tool if overall productivity is to increase and set up time reduced. The full range of Tornos single-spindle and multispindle turning machines is designed to enable tools to be pre-configured ("pre-setting") in 'masked time' mode. System measurements can be taken in mm and / or in inches. Component conveyor belt Parts can be transported outside machining area without risk of shock. Can then be interfaced with other component handling / gripper systems. Parts retrieval systems by handling (handler) and pallet (pick and place system) Enables machined components to be placed on standard pallet systems. Specially designed to optimise production in the medical and dental sectors, where parts are usually of the same shape and size. 23

24 Peripherals Wide range of peripherals available depending on market needs Fire protection systems Depending on the material being machined (mainly titanium), the medical and dental sectors must be equipped with fire extinguishing systems. This system operated with two independent systems which are actuated when flames are detected or when the temperature exceeds a certain level. Co 2 extinguishing is a "clean" solution which enables production to be started up again immediately. Oil cooling / heating device The system is equipped with two functions : a) cooling the cutting liquid to maintain a constant temperature inside the machine and achieve an extremely high level of precision through thermal stability. b) oil heating system which rapidly warms up the cutting liquid when turning machine starts up and then stabilises the temperature. The warming up time of the turning machine is considerably reduced. A timer delay system enables the system to be turned on before the operator starts work. 24

25 Peripherals Wide range of peripherals available depending on market needs Interfaces for measuring system and automatic corrections of machined dimensions (off-line) Enables dimensions to be measured automatically (diameters and lengths) on the turning machine during production. An interface transfers the correction values to the machine control unit directly from the customer s measuring system. Oil mist and fume extractors Different systems are available to extract oil mists and dry fumes during machining. A braking device blocks fume and mist extraction if a fire protection system is triggered. Swarf conveyors Different conveyor systems are available depending on customer requirements and types swarf. There are standard conveyor systems for long and thin swarf (belt or scraper conveyors), as well as automatic systems for all types of swarf (short and long) with cutting liquid filtration. There are also options available for fine swarf filtering and paper filter or decantation systems (for brass, aluminium, titanium or stainless steel swarf). The reputation of Tornos is based on its innovative solutions. Our priority : develop products which meet your requirements in terms of machining functionality and capabilities. Any necessary peripherals can be adapted at any time on our products. Tornos is extremely active in the area of development and collaborates closely with numerous suppliers in the tooling, peripherals, equipment, cutting oils and materials, with the aim of offering its customers machining solutions which are tested and adapted to the different requirements of the market. 25

26 Tornos provides solutions to high-technology industries, in the following sectors in particular : Automotive Electronics Watchmaking & Micromechanics 26

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28 Tornos S.A. Rue Industrielle 111 CH-2740 Moutier Tel. +41 (0) Fax +41 (0) Tornos-Technologies Deutschland GmbH Karlsruher Str. 38 D Pforzheim Tel. +49 (0)7231 / Fax +49 (0)7231 / contact@tornos.de Tornos Technologies Italia SRL Via Cesare Pavese 21 I Opera / MI Tel Fax contact@tornos.it Tornos Technologies US Corporation 70 Pocono Road P.O. Box 325 US-Brookfield CT Tel Fax contact@tornosusa.com Tornos Technologies Asia Limited Unit 4, G/F, Transport City Building 1-7 Shing Wan road Tai Wai, Shatin N.T., Hong Kong Tel Fax asiapacific.contact@tornos.com Tornos Technologies France Boîte postale 330 St-Pierre en Faucigny F La Roche s / Foron Cedex Tel. +33 (0) Fax +33 (0) contact@tornos.fr Tornos Technologies UK Ltd Tornos House Whitwick Business Park Coalville UK-Leicestershire LE67 4JQ Tel. +44 (0) Fax +44 (0) sales@tornos.co.uk Tornos Technologies Iberica Pol. Ind. El Congost Avda. St Julia, 206 Nave 8 E Granollers Tel Fax commercial.tti@tornos.com Tornos shanghai Representative office Tower B, Office Far East International Plaza No. 319 XianXia Road CN-Shanghai Tel Fax china.contact@tornos.com Conforms to the European CE / CEM Safety Standards This document is based on information available at the time of publication. While every effort has been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware and software, nor to provide for every possible contingency in connection with installation, operation and maintenance. TORNOS S.A. assumes no obligation of notice to holders of this document with respect to changes subsequently made. TORNOS S.A. makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency or usefulness of the information contained herein. No warranties of merchantability nor fitness for purpose shall apply. Edition 4 / 2007