Medical en Tornos

8/12/2019 Medical en Tornos

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T H I N K P A R T S T H I N K T O R N O S

MEDICALProven solutions in the medical sector

for over twenty years.


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2 Medical

A deep knowledge of the market and its needs

enables us to develop machines and machining

processes best suited to produce the different

medical components.

Tornos offers such solutions in response

to the demands and quality requirements of

its customers.

Orthopaedy and traumatology

Area of the spine

Surgical instruments

Dentistry

Orthodontics

Cardiology

Tooling

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 approaches

to machine parts up to 32 mm in diameter

on our line of single spindle and multispindles

lathes and machining centers to

produce 100x100x100 mm cubic parts.

Competition means that Medtech

manufacturers and subcontractors are under

ever-increasing pressure to reduce prices.

This must not affect zero defectswhich must

be enforced. Dependable and highly productive

production methods are paramount.A challenge taken up by Tornos with its

machining solutions.

THE CHALLENGE OF THE MEDICAL INDUSTRY

Single spindle

machines

Machining

centers

Multispindle

machines

Peripherals


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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. Our knowhow goes from turning to

milling and every other material cutting operation

needed to produce components for the medical

industry. The objective is to complete components

without any secondary operation. We will advise

you on the best machine kinematic, machining

performance, attachments and tooling.

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 exper-

tise we have acquired in materials specific to this

field, (e.g. stainless steel for implants, titanium,

peek, biodegradable materials, Co-Cr, ceramic,

etc.), we offer the best tools and machining con-

ditions to optimise cycle times and increase pro-

ductivity.

The manufacture and production of specific com-

ponents, of assemblies indeed, constitute a veri-

table challenge that we are ready and eager to

take on.

By virtue of their experience and expertise which

have been built up over more than twenty years

working in this sector, Tornos develops products

which meet the needs of the market, high-performance equipment in terms of machining

and reliability, new software developments, as

well as machine features and other programming

options, CADD Compatibility, OEE Interface (0ver-

all Equipment Effectiveness), robotisation, auto-

misation 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 worlds only manufacturer to offer

machining solutions dedicated to the Medtech

industry on single spindle, multispindle or machin-

ing centers. Product ranges, their technical speci-

fications and their performances are dedicated to

machining parts of mid- to high-level complexity :

Sliding headstock machines : product line

of Delta, Gamma, Micro, Sigma, DECO and

EvoDECO.

Multispindle machines with fixed spindles :

product line MultiAlpha (6 and 8 spindles) and

MultiSigma.

Work from barstock Tornos FB1005 and

PB 700 milling machines, ultra precise Tornos

CU 1007 machining center for work from

barstock or blanks.

Peripherals

AdviceServices /Support

Customisedmachining Turn Key


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its 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 340 bar, stamping, the realisa-

tion of complex forms by HSM milling (i.e. milling

of Torx, milling by polar coordinates), is pos-

sible 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 machin-

ing times for each operation at the bar and in

counter operation are evenly distributed and

well-balanced which in turn improves productiv-

ity. 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.

The flexible configuration of our machining cent-

ers can precisely be adapted to your needs no

matter how demanding they can be. We can,

for example, refer to the experience we have

acquired in the machining of hard ceramic with

machine elements and protections in stainless

steel (CU 1007).

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 implica-

tions into account.

A TRIED AND TESTED CONCEPT


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A SOLUTION FOR EVERY TYPE OF PART

Example : maxillofacial screws, micro screws and dental implants

Example : trauma and orthopaedic screws with complex dental

implants and abutments

Example : trauma orthopaedic and spine (mono and poly axial)

screws, nails, hip screws.

Maxillofacial screws

Humeral locking screws

Schanz screws

Guide wires

Dental implants

Dental abutments

Caps / screws Drill / reamers

Sleeves / connectors

Bone screws

Cannulated / corticalis screws Corticalis / malleolar screws

Humeral locking screws

Locking screws

Trocar

Connecting rods

Drill sleeves

Distraction / compression rods

Dental implants

Angled abutments

Drill / reamers

Cannulated screws

Nails

Lag / hip screws

Mono / poly axial screws

Spine hooks

Poly axial heads

Connecting rods

Tooling Nuts

EvoDECO 10a / 10e

EvoDECO 16a / 16e

DECO 20a / 20e / 26a / 26e


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FOR MACHINING YOUR PARTS WITHOUT

SECONDARY OPERATION

Example : screws for implants, covers, simple abutments.

Bone screws

Locking screws

Corticalis screws

Connecting rods

Nails

Nuts

Tooling

Sigma 20 / 32

Gamma 20

Delta 12 / 20 Micro 7 / 8

Example : screws for implants, covers, simple abutments.

Bone screws

Dental implants Abutments

Tooling

Dental abutments

Caps / screws


Dental abutments

Caps / screws



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MultiSigma 8x28

Simple counter operations

MultiAlpha 8x28 / MultiAlpha 6x32

Complex counter operations

Example : orthopaedic nut, screw

Example : Poly axial head, orthopaedic nut, screw

Bone screws

Implants

Polyaxial heads (spine)

Bone screws

Implants

FOR MACHINING YOUR PARTS WITHOUT

SECONDARY OPERATION


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SOLUTION PROVIDER

Chip conveyors

Bar-feeders

High pressure pumps

Machining andprocessing

Oil and air filters

Burring

Manipulating

Pallettising

Part-feeders

Cleaning

Partsmeasurements

Robotisation


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PRODUCTS PERFECTLY SUITED

TO YOUR REQUIREMENTS

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, measur-

ing, operator and environmental protection).

Tornos EvoDECO 16a


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T41

T53

T51

T42

T42

T43

T14

T24

T15

T12

T21

T31

T32

T33

T15

T13

T23

Medical

PRODUCTS PERFECTLY SUITED

TO YOUR REQUIREMENTS

Dental abutments (for implant) in titanium

Realization on Tornos EvoDECO 16a


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Z48

Y48S58

S18S17S16S15S14

S11S12S13

S48

X11

Z11

MS1 X12

Z12

X13

Z13

Z21

Z22

Z23

9.2

9.3

8

7

6

4

3

1

2

5

Medical

MACHINING SEQUENCE

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.

Locking motorfor the barrel

Motor for rotating tools of thecounter-operations pos. 8

Counter-spindlemotor in pos. 8

Titanium 15,5 mm lg. 17,2 mm

Tornos MultiAlpha 8x28


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MACHINING SEQUENCE

Tornos FB 1005 Milling center

Numerical B axis.

3 independent tooling systems

(steady and rotating).

Machining of PEEK.

Tornos FB 1005


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MEDICAL APPLICATIONS

Maxillofacial, orthopaedics, trauma, hip screws

Titanium

Titanium

Titanium

Titanium

Titanium

Titanium

Titanium

Titanium Steel 316 L

Steel 316 L

Steel 316 LSteel 316 L

Titanium

Steel 316 L

Steel 316 L

Titanium Steel 316 L

Titanium

Titanium

Steel 316 L TitaniumSteel 316 LSteel 316 L


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Tooling, components

Steel 316 L Titanium

Stainless Steel 304

Stainless Steel 304


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Implants /dental components

Titanium

Titanium

Titanium

Titanium

Stainless steel 316 L

Titanium

Titanium

Titanium

Titanium

Titanium




Titanium



Titanium

Titanium Titanium Titanium

Zirconia Cobalt ChromeTitanium Titanium X5CrNiCuNb 16-4


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z

s

c

x

Medical

MACHINING TECHNOLOGY

Internal thread-whirling process

(main operations and counter operations)

Benefits of the process

Low cutting forces due to different cuttingedges 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

resharpened (regular profiled blades / approx.

40-60 times possible resharpenings)

Machining technology with constant profile

cutting tools or inserts.

Cutting tools are pre-set before enteringmachine and rapid assembly / disassembly of

tool holder head.

Angling of the whirling head according to the

thread helix (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.

Internal thread-whirling at the bar and in coun-

ter operation in 'masked time' mode.

Spindle 80000 rpm

Tool 1 mm

Principle diagram for internal thread-whirling process

Internal thread-whirling tool


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Boring / drilling deep bores at high pressure 120 / 340 bar

Using a high pressure cutting liquid (up to

340 bar) for boring deep bores is often essen-tial 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 50-60 x

the diameter), depending on shape of part.

The high pressure systems (from 120 to

340 bars) can be adapted on most our productline equipped with a standard interface and

the integration is possible on the entire line of

single and multispindle machines.


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Boring / drilling deep bores at high pressure 120 / 340 bar

Milling of the self tapping forms

To facilitate the implantation of the screw

into the bone mass, the implants must be self

tapping to ease the penetration.

Thanks to the use of specific attachments

and cutting tools, its possible to achieve

these operations, either in main operations

(at the bushing) or in counter operations.

The use of thread whirling process eliminate

any burrs resulting from the milling of the self

tapping features.

View of a screw about 120 mm long with the various pre-settable tools used to produce it.


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Machining Torx shapes and other specific high-speed milling applications

Medical applications occasionally require mill-

ing / drilling with extremely small-sized tools.High-speed spindles are also key to achieving

optimum cutting parameters and the required

finishes.

High-frequency spindles enable rotation speeds

of up to 80000 rpm to be reached.

These operations can be carried out on the turn-

ing machines both as main operation and as

counter operation in 'masked time' mode.

The same high-frequency spindles are used for

internal thread-whirling operations and other

end / transverse operations which require high cut-

ting 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.

Suppression of microburrs thanks to

the high cutting speed and the use of small

cutting tools.


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Machining specific shapes with the stamping process

Some components especially for the spine,

orthopedic nails and dental implants, 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.

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.


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Simultaneous 5 axis machining

Available on our machining centers CU 1007

and FB10055 axis machining gives you the freedom to

quickly produce complex shapes on a single

machine. It is then possible to angularly position

the part on 2 axes so to effectively drill or mill

at different angles. It is also possible to do 5 axis

interpolation for deburring operations, as well

as milling complex forms with the help of the

continuous interpolation of the machines 5 axes.

Advantages

Machining of complex shapes. Possibility to angularly position the part.

Possibility to simultaneously interpolate

the 5 axes of the machining center. Reduces

to use of form tools.

Enables to work from barstock or blanks.

Significant gain of time, enables to machine

complex forms in one clamping.


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PERIPHERALS

Wide range of peripherals available depending on market needs

Fire protection systems

Co2extinguishing is a clean solution which

enables production to be started up again imme-

diately.

Part conveyors

These conveyors can be integrated with other

part handling systems.

Coolant cooling or heating systems

The temperature regulators maintain the cuttingfluid at a constant temperature allowing for high

precision machining.

Swarf conveyors

2 swarf conveyor systems are offered.

A standard system and one with a drum type

filtration system.

6 axis robot

The integration of high performing

6 axis robot offers an unequaled

autonomy of movements.

Oil mist extractors / filters

The filters are available in three versions : mechan-ical filters (HEPA H13), electro-static filters,

mechanical adaptations for centralized systems.

Paper filtration

Enables to get an optimal

cleanliness and increases the

life span of the cutting oil.

Stainless coolant tank (Zirconia)

Stainless coolant tank with a 30 microns cartridge

filter. Capacity : 100 liters, output : 40 l / min.


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11T

ornos2011,allrightsreserved

cm

TORNOS S.A.

Rue Industrielle 111

CH - 2740 Moutier

Tel. +41 (0)32 494 44 44

Fax +41 (0)32 494 49 03

[email protected]

www.tornos.com

TORNOS TECHNOLOGIESDEUTSCHLAND GmbH

Karlsruher Str. 38

D - 75179 Pforzheim

Tel. +49 (0)7231 / 910 70

Fax +49 (0)7231 / 910 750

[email protected]

TORNOS TECHNOLOGIES

FRANCE

Bote postale 330

St-Pierre en Faucigny

F - 74807 La Roches / Foron Cedex

Tel. +33 (0)4 50 038 333

Fax +33 (0)4 50 038 907

[email protected]

TORNOS TECHNOLOGIES

IBERICA

Pol. Ind. El Congost

Avda. St Julia, 206 Nave 8

E - 08403 Granollers

Tel. +34 93 846 59 43

Fax +34 93 849 66 00

[email protected]

TORNOS TECHNOLOGIES

ITALIA SRL

Via Cesare Pavese 21

I - 20090 Opera / MI

Tel. +39 02 57 68 15 01

Fax +39 02 57 68 15 230

[email protected]

TORNOS TECHNOLOGIES

UK LTD

Tornos House

Whitwick Business Park

Coalville

UK - Leicestershire LE67 4JQ

Tel. +44 (0) 1530 513100

Fax +44 (0) 1530 814212

[email protected]

TORNOS TECHNOLOGIES

(Shanghai) LTD

Hui Feng Creativity Garden

Feng Yu Building, 1-2F

No. 239, Xitai Rd, Xu Hui District

CN - Shanghai 200232

Tel. +86 21 6235 1235

Fax +86 21 6235 1938

[email protected]

TORNOS S.A. THAILAND

REPRESENTATIVE OFFICE

Flat 1B, The U.N. Residence

27/28 Sukhumvit Soi 33

Bangkok 10110

Thailand

Tel. +66 2 662 3908

Fax +66 2 662 3910

[email protected]

TORNOS TECHNOLOGIES

US CORPORATION

840 Parkview Boulevard

US - Lombard, IL 60148

Tel. +1 630 812 2040

Fax +1 630 812 2039

[email protected]

www.tornos.us

TORNOS BEIJING OFFICE

Rm.1706, Tower A

Dongyu Office Building

Jia #1 Shuguang Xili

Chaoyang District

CN - Beijing 100028

Tel. +86 10 5979 8583

Fax +86 10 5822 0483

[email protected]

TORNOS TECHNOLOGIES

ASIA LTD

Unit 4, Ground Floor, Transport City

Building

1-7 Shing Wan Road

Tai Wai, Shatin

N.T., Hong Kong

Tel. +852 2691 2633

Fax +852 2691 2133

[email protected]

TORNOS TECHNOLOGIES ASIA LTD

MALAYSIA

REPRESENTATIVE OFFICE

K-7-1, Lorong Bayan Indah Dua,

Bay Avenue, 11900 Pulau Pinang,

Penang, Malaysia

Tel. +6 04 642 6562 / 642 6563

Fax +6 04 642 6561

[email protected]

TORNOS TECHNOLOGIES

POLAND Sp. z o.o.Ul. Brukselska 44 lok. 21A

PL - 03-973 Warszawa

Poland

Tel. +48 226 72 91 81

Fax +48 226 16 55 81

[email protected]

TORNOS DO BRASIL, Ltda

Av. Dr. Cardoso de Melo,

1470 Conj. 604

BR - 04548-004 Vila Olmpia

So Paulo - Brasil

Tel. +55 11 3045 6695

[email protected]

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Medical en Tornos