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5-axis CNC machining of medical titanium alloy locking plates (TC4) case study
Release time:
Oct 15,2024
Background
In the medical field, locking plates, as an important instrument for repairing fractures, have strict material and machining requirements. This case study demonstrates Yixin Precision's successful experience in using 5-axis CNC technology to machine TC4 titanium alloy locking plates.TC4 (Ti-6Al-4V) has become the material for medical implants due to its excellent biocompatibility, high strength, light weight and corrosion resistance. However, TC4 is also recognized as a difficult material to be machined, making it a challenge to accurately machine locking plates that meet medical standards.
Material and Technical Challenges
The main machining challenges for TC4 titanium alloys include:
Poor thermal conductivity: Heat generated during machining cannot be quickly dissipated, which can lead to tool overheating and shortened its life.
High strength and toughness: This increases cutting forces and tool wear during machining.
Elastic deformation: TC4 has a low modulus of elasticity and is prone to small deformations during machining, especially when manufacturing high-precision medical devices.
Therefore, machining such parts requires high-precision equipment with strict process control. 5-axis CNC machines can provide advantages in these areas, including reducing errors associated with multiple clamping and the ability to machine complex surfaces in a single pass.
Advantages of 5-axis CNC machining
Yixin Precision uses advanced 5-axis CNC technology, and the main advantages include:
High accuracy: 5-axis CNC is able to complete the machining of complex geometries without the need to reposition the part multiple times, significantly improving machining accuracy.
Complex Surface Machining: Locking plates are often designed to conform to the natural curvature of the human skeleton, and the 5-axis linkage allows complex surfaces to be easily machined from multiple angles.
Reduced clamping times: One clamping can complete all-round machining, which reduces the time for repetitive positioning, improves machining efficiency and reduces potential errors.
| Product Name | Medical Titanium Splint |  |
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| Machining Equipment | 5-Axis CNC | ||||||
| Size | 118 mm*25 m*50 mm | ||||||
| No. of CNC Machining Tools | 12 | Total Time | 3h 10min | ||||
| Details No. |
Processes | Tool | Ap (mm) | Ae (mm) | Spindle Speed （rpm) |
Feed Rate (mm/min) |
Machining Time |
| 1 | Pre-machining | D10R1 | 24 | 0.8 | 6000 | 3000 | 0:06:50 |
| 2 | Fine-machining | D6R3 | 0.06 | 0.14 | 9000 | 3000 | 0:40:50 |
| 3 | Drilling | D3 | 2 | － | 3000 | 100 | 0:03:10 |
| 4 | Clearance | R0.5 | 0.04 | － | 18000 | 6000 | 0:01:50 |
Parts Highlight： 1.D10－D0.5mm tools machining is completed in one time. 2.The tool setting error of the curved surface is within 10um. 3.High surface finish reduce the workload of grinding or polishing process. |
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| Inspection Item | Inspection Report | ||||||
| Inspection Position | 1 | 2 | 3 | 4 | 5 | 6 | |
| Precision Deviation(mm) | -0.011 | -0.014 | -0.008 | -0.006 | -0.078 | -0.067 | |
| Roughness Ra(µm) | 0.646 | 0.705 | 0.655 | 0.615 | 0.645 | 0.585 | |
| Inspection Equipment | HEXAGON CMM | ||||||
Machining process
In order to ensure the accuracy and surface quality of the locking plates, Yixin Precision follows the following machining steps:
1. Design and Programming: According to the CAD drawings provided by the customer, Yixin Precision's engineering team programs the machining paths of the parts in detail, especially for curved surfaces, to ensure that the machining paths are consistent with the design.
2. Roughing and Finishing: 5-axis CNC is used for roughing to remove most of the material, then by finishing to ensure that the required dimensional accuracy and surface finish are achieved.
3. Surface treatment: In order to meet the strict requirements of medical devices, the locking plates are subjected to surface treatment after machining, such as deburring and polishing, to ensure that their surfaces are smooth and free of defects.
Quality control
In the production of medical devices, quality inspection is crucial. In order to ensure the various performances of the locking plates, Yixin Precision has implemented the following quality control measures:
Dimensional Inspection: Use high precision Coordinate Measuring Machine (CMM) to inspect the key dimensions of the plate to ensure that they meet the tolerances.
Surface quality testing: Microscope inspection of the surface for burrs, cracks or other defects that may affect implantation safety.
Mechanical performance testing: Finished products are tested for tensile strength, fatigue strength, etc. to ensure their durability and reliability in actual use.
Compliance requirements for the medical industry
As a medical device, the production of locking plates needs to meet strict industry standards. Yixin Precision also has the certification of ISO 13485:2016 for medical device quality management system. Yixin Precision strictly follows the ISO 13485:2016 quality management system for medical devices to ensure that every step of the process, from material procurement, processing to testing, meets the standards. In addition, TC4 titanium alloy locking plates must pass a series of biocompatibility tests to ensure their safety and stability in the human body.
Conclusion
This case study shows that Yixin Precision has successfully utilized 5-axis CNC technology to solve the challenges in TC4 titanium alloy machining, ensuring that the locking plates meets high standards in terms of biocompatibility, mechanical strength and surface quality. This case not only demonstrates Yixin Precision's technical strength in the processing of difficult materials, but also shows its excellent experience and ability in the field of medical device manufacturing, providing customers with products that meet the strict requirements of the medical industry. It also highlights Yixin Precision's innovative ability in the medical field and its advantage in providing customized high-precision parts solutions.
5-axis CNC machining, TC4 titanium,TC4 titanium alloy locking plates,Yixin Precision,CNC machining of medical devices
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