DEVELOPMENT OF PRESSING/CUTTING HYBRID MACHINING SYSTEM FOR MANUFACTURING MEDICAL MICRO TOOLS

(1)研究背景与目的随着近年来医疗水准的极高。医疗器械的重要性越来越大。大多数医疗器械具有复杂的形状，其生产需要先进的技能和相当长的时间。因此，这些产品变得昂贵。在这项研究中，一个系统的加工复杂的医疗设备可靠地已被开发。(2)结果作者已经开发出一种新的微加工/微成形系统的辅助模具技术。经验证，该系统可用于在短时间内经济地生产微小零件。用该丝制作了医用微型镊子样品。本研究针对医用微小型零件之制造，提出一种较先进之系统，其包括材料处理单元及三个成型单元：模具单元、旋转模具单元及切割单元。模具单元使原材料通过变形过程产生复杂的形状， 关于我们 例如锻造、剪切和冲裁。可旋转模具单元使原材料能够形成具有锯齿形轮廓的零件。这些单元在刀库杂志上有大量的刀具，因此，可以实现各种成形。然而，就使用普通工具而言，形成自由的不规则图案是不容易的。为了克服这个问题，增加了微切割单元。该设备是一台精密高速微型铣床。值得注意的是，我们新开发了一种非常小的工具（20-30μm），能够加工各种复杂形状的零件。即利用该系统可以实现模具技术的大变形，并在模具技术难以实现的地方采用切削技术。本研究的另一个重点是微切削系统的开发。普通立铣刀形状复杂，尺寸较小的立铣刀加工难度较大。这意味着三维部件的微切割也很困难。为了克服这个问题，我们提出了一个简单的切割微铣刀专门用于微加工。设计了精密切割装置。该微磨机由空气轴承支撑的50，000 - 10，000 rpm的高速主轴电机驱动。实验结果表明，可以在铝丝上制作出一定的微图案。也可以制造15-25 μm宽的图案的窄部分。这些结果表明，该系统可用于创建三维自由形式的微图案。少

(1) Background and Purpose of ResearchWith the extremely high standard of medical care in the recent years. The importance of medical devices is ever more increasing. Most medical devices have complicated shapes, and their production requires advanced skills and considerable time. These products thus become expensive. In this study, a system for machining complicated medical devices reliably has been developed.(2) ResultsThe authors have already developed a new microfabricating/microforming system with the aid of did mold technology. It was ascertained that the system is available for producing micro parts in a short time economically. The medical micro-forceps as a sample was made from this wire. This research treats more advanced system suitable for fabricating the medical micro parts, it consists of material handling unit and three forming units ; die unit, rotatable die unit and cutting unit. The die unit enable the raw material to create a complex shape by the deformation processi … More ng such as forging, shearing and blanking in a very short time. The rotatable die unit enables the raw material to form parts having zig-zag contour. These units have a large number of tools on the tool stock magazine, so that, a variety of forming can be achieved. Though, the forming of a free irregular pattern is not easy as far as the ordinary tools are used. In order to overcome this problem, the micro-cutting unit is added. This unit is a precision high-speed micro milling machine. A notable point is that a very small tool(20-30μm) is newly developed by us and is capable of parts various complex shape. Namely by using this system, a large deformation can be performed by the die mold technology, and cutting technology is used as where the die mold technology can not easily be applied.The other important point of this research is development of micro-cutting system. A ordinary end-mills shape is so complex, the small dimensional sizes are more difficult to fabricate. This means that the micro-cutting of three-dimensional components is also difficult. To overcome this problem, we proposed a simple oblique-cut micromill to be used exclusively for micromachining. A precision cutting device was also designed. The oblique-cut micromill is driven by a high-speed spindle motor of 50,000 - 10,000 rpm supported by air bearings. Results of experiments show that certain micropatterns can be fabricated on aluminum wire. Narrow parts of patterns that are 15-25 μm wide can also be fabricated. These results indicate that the system can be used to create three-dimensional free-form micropatterns. Less