The Tsugami TMA8F is shown machining 1 of 2 components used in an elbow replacement implant assembly at IMTS.
Due to the implant’s long, slender profile and fine details, this part was machined in sections. The thru-spindle fed bar-stock acts as the fixturing for the component, as machining is gradually performed along its length.
Through a prime-turning operation, a large majority of the material is removed, and the front end of the part begins to take shape. 3, 4, and 5 axis milling operations come next to rough, finish, and surface the features that hang so far out in front of the part.
With the front features fully finished, high-feed milling operations begin to shape the middle of the Implant. The full range of the 20,000RPM & 15HP B-axis tool spindle is utilized to rough and finish this second section of the component. Heavy milling with a chip-thinning shell mill, high speed end milling, engraving, surfacing, and finishing are all necessary to drop this part complete in just 1 setup.
Roughing the back-side contour, cutting off the part, and transferring the component into the A-axis sliding Sub-Spindle, are combined into just 1 operation.
The third and final section of the Elbow Implant is completed in its entirety while being securely held in a Schunk 2-jaw chuck, with custom milled jaws. First, an end mill is used to finish the rear profile and qualify the flat faces. The thru holes are formed by helically interpolating from each side. Another small end mill is used at high RPMs to allow a slotting operation between the two “ears” on the rear of the part. A Ø2mm ball end mill surfaces the dynamic radius floor at the bottom of the previously formed slot. Lastly, full 5-axis deburring toolpaths are used to radius all edges on the rear features of the Elbow Implant, the part is dropped into a parts catcher, new material is autonomously pushed through the spindle into the working area, and the next part cycle begins.