Published 12/7/2010

Five-Axis Automation for Medical Machining

Methods Machine Tools’ RoboDrill Med Cell is a complete pre-engineered, fully integrated production machining cell that automates loading and unloading of medical device parts.

Edited by: MMS Editorial Team

Methods Machine Tools’ RoboDrill Med Cell is a complete pre-engineered, fully integrated production machining cell that automates loading and unloading of medical device parts. The machining cell has full five-axis capability and is designed for medical machining applications including short-run production of parts in materials ranging from stainless steel to titanium.

With a fully integrated six-axis robot, the cell automates loading/unloading. The high-speed FANUC LR Mate 200iC robot features grippers, a teaching pendant and several customizable programs. The package also includes fully interfaced inbound and outbound conveyors and guarding that are customized to receive the integrated macro chuck for full lights-out automation.

The compact machining cell is designed for simple installation, fast setups and change-overs, operator safety and production flexibility. The integrated macro chuck enables different parts to be mounted on the same universal chuck base for maximum versatility. The cell can be configured to handle virtually any part that will fit in its 6" vise or chuck. The workpiece is pallet mounted, ensuring that parts remain aligned when moved through other production operations to improve rigidity and accuracy. The cell incorporates a compact, custom-engineered drop trunnion rotary table that positions the table faceplate close to the table surface.

The heart of the cell is the RoboDrill VMC, which is designed for continuous five-axis machining via optional CAMplete software, designed for exotic materials. RoboDrill offers a 14-tool (optional 21-tool) tool changer; a 10,000- or 24,000-rpm spindle; torque ranging to 56 foot-pounds; rigid tapping to 5,000 rpm (8,000 rpm optional); accelerations in X, Y, and Z axes to 1.5 G; rapid traverses to 2,125 ipm; feed rates to 1,181 ipm (2,362 ipm optional); high speed reverse tapping; thread milling; 1,000 registerable programs; and 54 work offsets.

The cell can also be modified for use in turning applications in conjunction with a Nakamura CNC lathe. An optional graphite machining package is also available, and a vision system can be added to identify parts of differing sizes.