Medical Testing Equipment

Case Sharing – One Part on Medical Equipment Automatic Assembly

Service: CNC; Milling machining; Grinding machining; Anodizing

Material: SUS420J2

Quantity:5 parts/module, 2 small modules; each module demand 200 SET/ month

Customer:

It is a world-famous automation manufacturer of medical equipment and automobile assembly, with rich experience in precision automation improvement and innovative solutions.


Customer Comments:

KANOU Group has rich experience in mechanical automation parts manufacture and assembly. In the early communication, KANOU team provided a lot of suggestions, on no matter the small module assembly or parts machining, they not only met the assembly requirements, but also did cost saving.


Product:

This is a part used on the automatic production line of medical equipment assembly. Base on the characteristics of large-scale mass production of automatic production line, the product design process is advanced, stable and reliable, remaining unchanged for long time. We provide a single variety of parts which can be mass produced, to meet the requirements of various application scenarios of the production line, including unit systems such as transportation, assembly, testing, packaging, automatic control, etc.


Meanwhile, the reduction of labor force leads to the increase of labor cost, and it is urgent to speed up automatization of production line. Due to the characteristics of multiple varieties and small batches in the field of medical equipment, it’s necessary to consider not only the commonality of small modules, but also practicability, when promoting automatic production.


Project:

After receiving customer's inquiry, we carried out investigation on the application scenario.


Whether the precision of parts or the tolerance after small die assembly, the key dimension tolerance of parts is required to be 0.002mm min, and the assembly tolerance is required to be 0.005mm min.


It requires us to make more specific considerations strictly in the arrangement of materials and processes, as well as the usage of cutting tools and machine tools.

Medical Equipment Automatic Assembly Parts

Medical Equipment Automatic Assembly Parts

Medical Equipment Automatic Assembly Parts

Medical Equipment Automatic Assembly Parts

Medical Equipment Automatic Assembly Parts

Medical Equipment Automatic Assembly Parts

Processing Highlights:

Challenge 1:

Material usage:


As shown as below table, the different hardness of stainless steel after heat treatment impacts greatly on machining. By using the turning tools made of cemented carbide YW2, we can see the different effects from the turning conditions with different hardness after heat treatment. Although the hard bottom becomes lower after annealing, the turning performance is not good, because the material has large deformability and toughness, and the structure is uneven, and it’s not easy to obtain good quality of surface.


After quenching and tempering, the SUS material with hardness lower than HRC30 has good machinability and surface texture. The equivalent higher than HRC30, the surface roughness is well controlled, but the turning tool is seriously worn.


In the early time of project, we reached a consensus with our customer on quenching and tempering by consulting customer's specific purposes.



Challenge 2:

Selection of Cutting Tools


As we all know, when machining stainless steel, it is very easy to stick to cutting tool, it as well has serious loss on the turning tool. Compared with other materials, it is more difficult to process stainless steel.


We commonly use W18CR4V and W6M05CR4V2AL. Under the same cutting condition, we compare the turning effects of several materials. The TIC-TICN-TIN composite coating tool has high durability, fast cutting speed and finally obtained good surface texture. At last, we adopted SANDVIK tool. Although the cost of a single tool is high, the overall cost is well controlled.


Challenge 3:

Four axis CNC machining:


1. In R3 hole processing, the product height is 71mm, the outer diameter is 60mm. The processing height is 54mm, which is deep hole processing. Besides, it is easy to happen knife snap during stainless steel processing, with the tolerance requirement ±0.02mm.


2. Deburring of cross hole Matching SANDVIK tool, we used SANDEX 4-axis turntable for machining. In terms of structure processing, we adopted an external inclined arc chip breaking groove by external turning tool, to keep the chip curl radius large close to the tool tip, and the chip curl radius small close to the outer edge. The scrap turns to the direction remains to be processed and breaks, and the breaking surface is intact.


Finished Product

The finished parts and small module components have been delivered to the customer's development team, which is a successful delivery. In next step, module assembly and parts testing will be carried out to prepare for the subsequent small batch trial production of finished products. We are confident that the test will be successful and provide customers with guaranteed good products. It is worth to mention that the small module parts have passed the customer's test at one time.


It's a great project, and we hope to succeed in the coming overall testing phase of the finished product, and contribute to healthcare business. We are very proud that our small modules and parts have already one-time passed customer's test




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