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平的极高。医疗设备的重要性越来越大。大多数医疗器械形状复杂，其生产需要先进的技术和相当长的时间。这些产品因此变得昂贵。本研究开发了一套复杂医疗器械可靠加工系统。(2)结果利用微模技术开发了一种新型微加工/微成形系统。结果表明，该系统可在短时间内经济地生产微型零件。医用微型镊子就是用这种金属丝制成的。本研究研究了一种更先进的适合于医疗微零件加工的系统，它由物料搬运单元和三个成形单元组成；模组，可旋转模组和切模组。该模组可使原材料在极短的时间内，通过锻压、剪切、落料等多种变形过程，形成复杂的形状。所述可旋转模单元使所述原料能够形成具有锯齿形轮廓的零件。这些机组在刀架上有大量的刀具，这样，就可以实现多种成形。然而，就使用普通工具而言，自由不规则图案的形成并不容易。为了克服这一问题，增加了微切割单元。本机组为精密高速微铣床。值得注意的是，我们新开发了一种非常小的刀具（20-30μm），可以加工各种复杂形状的零件。即通过使用该系统，可以通过模具技术进行大的变形，并且在模具技术不容易应用的地方使用切割技术。本研究的另一个重点是微切割系统的开发。普通立铣刀的形状非常复杂，小尺寸的铣刀制造难度更大。这意味着三维部件的微切削也很困难。为了克服这个问题，我们提出了一种简单的斜切微铣刀，专门用于微加工。设计了精密切割装置。斜切微铣床由空气轴承支撑的50,000 - 10,000 rpm的高速主轴电机驱动。实验结果表明，在铝线上可以制备出一定的微图案。宽度为15-25 μm的图案的狭窄部分也可以制造。这些结果表明，该系统可以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