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Industry Case Studies
Over-All Solution Provider for Metal Cutting Tools
Tibial Tray of a Knee Joint Implant
Case Details
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Process step1. Rough machining of cavities, external contours, and weight-reduction slots 2. Semi-finish machining on the platform side and the bone side 3. Finish machining of the mating surfaces of the platform shims 4. Finish Machining of the Dovetail Lock Groove 5. Fine machining of the bone‑side fixation post and the intramedullary stem |
Specialized end mill for non-standard titanium alloysIn response to the low thermal conductivity, high cutting temperatures, and tendency to form built-up edges characteristic of titanium alloys and cobalt–chromium–molybdenum alloys, an Arno carbide solid‑carbide end mill specifically designed for titanium alloys is employed to perform rough milling of the tibial tray’s cavity, external contour, and weight‑reduction slots. This tool, combined with high‑pressure internal cooling that thoroughly flushes the cutting zone, effectively prevents heat buildup, thereby mitigating thin‑walled springback and dimensional drift. During the heavy‑stock‑removal phase, it can withstand high‑intensity continuous cutting loads, suppress the formation of built‑up edges when machining stainless steel or titanium alloys, and reduce abnormal tool wear, aligning with the high‑volume production rhythm of rough machining while establishing a uniform, consistent stock allowance for subsequent semi‑finishing operations. |
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Non-standard custom milling cutters / groove milling cuttersThis operation involves semi‑finishing milling on both the platform side and the bone side, covering the platform contour, the external shape of the fixation pins, and the weight‑reduction cavities. A combination of end mills and slotting cutters made from difficult-to-machine materials is employed, with strict control over the distribution of stock allowances. The toolpaths utilize layered climb milling and a low‑depth‑of‑cut strategy to prevent prolonged, continuous cutting in the same area, ensuring dimensional stability and uniform stock removal after semi‑finishing, thereby establishing a precise and consistent reference for subsequent finishing operations. |
Forming groove milling cutter, forming R‑corner milling cutterThe mating surface of the platform liner serves as the core assembly interface for the tibial tray, directly determining the reliability of liner retention and its long-term wear life. In this operation, a form‑groove milling cutter and a form‑radius corner milling cutter are employed to perform finish milling at small depths of cut, high spindle speeds, and low feed rates, ensuring the flatness of the mating surface. Finally, a finishing pass is applied to further reduce surface roughness, enabling milling to replace grinding and shortening the process flow. After machining, the mating surface is smooth and free of tool marks, effectively preventing common production‑stage issues such as excessive flatness deviation and non‑compliant surface roughness, thereby guaranteeing the long‑term stability of the liner fit. |
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Non-standard custom T‑shank milling cutters, non-standard custom chamfering milling cuttersThe dovetail locking groove features an inverted‑tapered geometry and represents one of the most challenging features to machine on the tibial tray. In this operation, a custom‑designed T‑shaped milling cutter and a custom‑designed chamfering end mill are employed, with multi‑pass, light‑cutting strategies that effectively prevent tool deflection and surface‑finish defects on the dovetail sidewalls. The tailored cutting edge geometry precisely matches the dimensions of the dovetail profile, enabling the locking‑groove contour to be formed in a single pass while consistently ensuring dimensional accuracy and superior surface quality on the dovetail sidewalls—eliminating the tool deflection, chatter, and form‑error issues commonly associated with standard tools used for machining inverted‑tapered features. |
Milling cutter for titanium alloys / cobalt-chromium-molybdenum alloysThe bone‑side fixation post and the intramedullary shank are thin‑walled, spatially curved structures that require four‑axis simultaneous multi‑axis machining. A dedicated milling cutter for titanium alloy and cobalt‑chromium‑molybdenum alloy is employed, with further reduction of the per‑pass depth of cut in the rod‑like sections to prevent machining chatter and thin‑wall deformation. Using multi‑axis simultaneous machining, the external contour of the fixation post and the curved surface of the intramedullary shank are precisely milled in a single clamping operation, thereby eliminating positioning errors associated with repeated setups and ensuring consistent precision in the conformal fit between the bone‑side curved surface and the underlying bone. This approach meets the stringent requirements for high precision and uniformity demanded by mass‑produced implant components. |
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