Technology Presentation

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Technology Presentation
Schütte CAD-CAM-Technology for Orthopedic
Components _______________________ presented
by Dr. Wilfried Saxler, David
Brigham, Ernst Fuchs January 29th,
2004
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Topics

• Introduction

2. CAD-CAM-Chain
3. Grinding Methods
4. Belt Grinding
5. Buffing
6. Milling
7. Automatic Tool Change
8. Methods of Handling
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Endoscopic Drills
Example for SCHÜTTE PC-Programming
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Hip ball
Previous 6 up to 8 step process, Several times
grinding with conventional wheels Several times
manually buffing Manual polishing Manual tool
changes Cycle time 20 to 30 min depending on ball
diameter
Example for long hand programming
Today 3 step process, Grinding with
electroplated CBN Wheel with adaptive
control, Buffing with pressure control Polishing A
utomatic tool change Cycle time 5 to 8 min
depending on ball diameter in single set up
Material Chrome-Cobalt-Alloy, casting, Hardness
55-57 HRC
Requested surface finish Mirror Image Ra
0,06 µm (CLA 2.4 µin)
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Single Knee, partial implant
Example single-knee, long hand programming

• 3 step process
• Grinding with electroplated CBN Wheel using
  adaptive control,
• Belting with pressure control
• Buffing with cloth wheel and compound

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Guide Arm
Example guide arm, long hand programming
Description of process multi cycle
procedure manufacturing in single set
up grinding with CBN grinding wheelspre-polishi
ng and finishing automatic tool change
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Double Knee
Example Double Knee, CAD-CAM-Application
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Hip Broach
Example hip rasp, CAD-CAM-Application
Process description single cycle
procedure machining in single setup grinding
with CBN grinding wheelsusing adaptive
control cycle time depending on broach size and
stock removal 30 to 45 min
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Hip Stem, Body Grinding
Example hip stem, body grinding, CAD-CAM-Applica
tion
Process description multi cycle
procedure machining in two setups grinding with
CBN grinding wheelsfinishing cycle time
depending on part size 18 to 20 min
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Hip Stem, Taper End
Example hip stem, taper end, CAD-CAM-Application
Process Description multiple cycle
procedure machining in single setup grinding
with CBN grinding wheelspre-polish and
finish automatic tool change cycle time
depending on part size 12 to 14 min
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Belting
• Milling
• Automatic Tool Change
• Methods of Handling

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Generating of NC-Programs by CAD/CAM
Software
Data file
CAD Computer Aided Design
CAM Computer Aided Manufacturing
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Generating of NC-Programs by CAD/CAM
CAD
Software
Data file
CAD Computer Aided Design
CAM Computer Aided Manufacturing
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Modeling in CAD
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Generating of NC-Programs by CAD/CAM
CAD
Software
Data file
CAD Computer Aided Design
CAM Computer Aided Manufacturing
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Generating Tool Paths with CAM system
3D-Model with Tool Paths
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Specialty of Unigraphics
ball nose cutter
grinding wheel
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Specialty of Unigraphics
contact situation unchanged
Interference between grinding wheel and
component
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Manufacturing in multiple axis
3-axis manufacturing

• swivel axis is fixed
• rotation of work-piece
• vertical movement by tool
• horizontal movement of
• work-piece after each line

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Manufacturing in multiple axis
5-axis manufacturing

• all 5 axis move simultaneously

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Generating of NC-Programs by CAD/CAM
CAD
Software
Data file
CAD Computer Aided Design
CAM Computer Aided Manufacturing
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Post processor method polar or linear
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Generating of NC-Programs by CAD/CAM
CAD
Software
Data file
CAD Computer Aided Design
CAM Computer Aided Manufacturing
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Calculating NC-paths (post processor)
complete NC program
NC-path as result of post processor
BPOS 0
CPOS 0
WHEEL_DIAMETER 0
WHEEL_SET_LENGTH LPAROPNR,38
WHICH_SPINDLE_END 1
SEGMENT 0
ACTIVE_SEGMENT SEGMENT
CALC_STARTPOS
NPV_X XPOS LPAROPNR,1
NPV_Y YPOS LPAROPNR,2
NC path universal NC
base program
NPV_Z ZPOS LPAROPNR,3
TRANS
TRANS XNPV_X YNPV_Y ZNPV_Z
G0 X-42.138 Y0.000 Z102.610 A-123.668 C0.000
G1 X-42.138 Y0.000 Z101.887 A-123.604 C0.000
Z99.952 A-123.236
Z98.198 A-122.634
Z96.707 A-121.815
Z95.557 A-120.810 ...
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Belting
• Milling
• Automatic Tool Change
• Methods of Handling

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Grinding
Advantages of line by line grinding ? only a
single tool is needed for
grinding of all sizes
grinding of right and left knee
grinding of straight and oblique
patella design
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Grinding
Contour grinding
Contour grinding using both sides of the wheel,
even the rear side of the radius
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Grinding
Roughness in circular direction ? depending on
tolerance parameter of
CAM system
and Siemens control compressor
value
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Grinding
Roughness in cross direction ? depending on
CAM parameter scallop
height and radius
of grinding wheel
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Disk Cutting
Tie bar
Grinding or cutting of tie bar
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Buffing
• Milling
• Automatic Tool Change
• Methods of Handling

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Belt Grinding
Belting Patella, following the contour, optionally
using adaptive control for controlling pressure
or feed of the tool
Belting Unit, specially designed by Schütte
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Belt Grinding
Contact Wheel with Abrasive Belt
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Belt Grinding
3M
Norton
3M Trizact Pyramid shape for higher abrasion

• Specifications differ in
• Grit-Size
• Coating
• Flexibility
• Structure

Norton randomly distribution of grits for higher
surface quality
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Buffing
• Milling
• Automatic Tool Change
• Methods of Handling

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Buffing
untreated
treated
Buffing Wheel
Treated and untreated cloth buffs
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Buffing
Compound Nozzle
Buffing Wheel in front of Compound Supply
Nozzle (also available with flexible arm for in
process supply)
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Buffing
Nozzle for Compound Supply
Compound Tank
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Buffing
Filtration unit must be able to filter residual
compound and cotton thread
Edge-Filtration-System
Centrifuge
Cartridge Typ
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Buffing
• Milling
• Automatic Tool Change
• Methods of Handling

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Milling
Milling might be necessary for surfaces, that
cannot be reached completely by the grinding wheel
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Milling
Endmill with coolant line
Milling the outside contour (simulation)
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Milling
Milling the box section
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Buffing
• Milling
• Automatic Tool Change
• Methods of Handling

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Tool Change
1.
4.
3.
2.
Magazine with 1. buffing wheel, 2. endmill, 3.
belting unit and 4. grinding wheel
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Topics

• Introduction
• CAD-CAM-Chain
• Grinding Methods
• Belt Grinding
• Buffing
• Milling
• Automatic Tool Change
• Methods of Handling

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Process Technology

• Possible Operations to be done by Schütte WU 305
  linear
• Grinding
• Milling
• Belting
• Buffing
• Gauging
• ..........

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Automated Gauging

• Automatic gauging with internal probe
• probing of requested contour point
• value detection
• internal calculation of measurement
• text ouput in data file

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Method 1 Description
Handling Method 1 Manual Part Loading
Mechanical Equipment - Basic Linear Machine
Operations done by WU 305 linear - Grinding
Tool Grinding Wheel CBN 1F1 Ø 6 - Milling
Tool HSC-Cutter - Belting Tool Abrasive
Belt - Buffing Tool Buffing Wheel -
Gauging Tool Internal Probe
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Method 2 Description
Handling Method 2 Automatic Machining of 8 Parts
Grinding and Milling Operations
only Mechanical Equipment - Basic Linear
Machine - Pick Up - Palette and Gripper
Fingers Operations done by WU 305 linear -
Grinding Tool Grinding Wheel CBN 1F1 Ø 6 -
Milling Tool HSC-Cutter - Gauging Tool
Internal Probe
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Method 2
Pick-Up-Loader
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Method 3 Description
Handling Method 3 Automatic Machining of 8
Parts Tool Setup for 8 Parts in the External
Tool Magazine Mechanical Equipment - Basic
Linear Machine - Pick Up - Palette and Gripper
Fingers - External Tool Magazine Operations
done by WU 305 linear - Grinding Tool
Grinding Wheel CBN 1F1 Ø 6 - Milling Tool
HSC-Cutter - Belting Tool Abrasive
Belt - Buffing Tool Buffing Wheel -
Gauging Tool Internal Probe
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Method 4 Description
Handling Method 4 External Robot In-Line to WU
305 linear for Belting, Buffing, Gauging and Part
Loading Mechanical Equipment - Basic Linear
Machine - External Robot ? ? ? Operations
done by WU 305 linear - Grinding Tool
Grinding Wheel CBN 1F1 Ø 6 - Milling Tool
HSC-Cutter
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