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8/12/2019 Medical en Tornos
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T H I N K P A R T S T H I N K T O R N O S
MEDICALProven solutions in the medical sector
for over twenty years.
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2 Medical
A deep knowledge of the market and its needs
enables us to develop machines and machining
processes best suited to produce the different
medical components.
Tornos offers such solutions in response
to the demands and quality requirements of
its customers.
Orthopaedy and traumatology
Area of the spine
Surgical instruments
Dentistry
Orthodontics
Cardiology
Tooling
Tornos have been pioneers in this sector for
over twenty years. By virtue of our developments
and practical expertise in the medical sector,
we are in a position to propose approaches
to machine parts up to 32 mm in diameter
on our line of single spindle and multispindles
lathes and machining centers to
produce 100x100x100 mm cubic parts.
Competition means that Medtech
manufacturers and subcontractors are under
ever-increasing pressure to reduce prices.
This must not affect zero defectswhich must
be enforced. Dependable and highly productive
production methods are paramount.A challenge taken up by Tornos with its
machining solutions.
THE CHALLENGE OF THE MEDICAL INDUSTRY
Single spindle
machines
Machining
centers
Multispindle
machines
Peripherals
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3Medical
OUR TECHNOLOGY AT YOUR SERVICE
for all types of parts.
You make highly demanding products, Tornos
can offer you proven solutions within a very wide
range of parts. We are at your disposal to find
a tailor-made solution for your manufacturing
process. Our knowhow goes from turning to
milling and every other material cutting operation
needed to produce components for the medical
industry. The objective is to complete components
without any secondary operation. We will advise
you on the best machine kinematic, machining
performance, attachments and tooling.
As far as the product is concerned, we offer
expert advice to guarantee you the best choice
in terms of kinematics, machining, equipment
and tooling performances. By virtue of our exper-
tise we have acquired in materials specific to this
field, (e.g. stainless steel for implants, titanium,
peek, biodegradable materials, Co-Cr, ceramic,
etc.), we offer the best tools and machining con-
ditions to optimise cycle times and increase pro-
ductivity.
The manufacture and production of specific com-
ponents, of assemblies indeed, constitute a veri-
table challenge that we are ready and eager to
take on.
By virtue of their experience and expertise which
have been built up over more than twenty years
working in this sector, Tornos develops products
which meet the needs of the market, high-performance equipment in terms of machining
and reliability, new software developments, as
well as machine features and other programming
options, CADD Compatibility, OEE Interface (0ver-
all Equipment Effectiveness), robotisation, auto-
misation in order to anticipate the needs of the
market and meet their customers expectations.
In the different sub-sections of Medtech (trauma,
spine, orthopaedics, dentistry, tooling, etc.),
requirements are not always the same.
The optimum machining method for this type of
part must therefore be selected.
Tornos is the worlds only manufacturer to offer
machining solutions dedicated to the Medtech
industry on single spindle, multispindle or machin-
ing centers. Product ranges, their technical speci-
fications and their performances are dedicated to
machining parts of mid- to high-level complexity :
Sliding headstock machines : product line
of Delta, Gamma, Micro, Sigma, DECO and
EvoDECO.
Multispindle machines with fixed spindles :
product line MultiAlpha (6 and 8 spindles) and
MultiSigma.
Work from barstock Tornos FB1005 and
PB 700 milling machines, ultra precise Tornos
CU 1007 machining center for work from
barstock or blanks.
Peripherals
AdviceServices /Support
Customisedmachining Turn Key
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5Medical
its a question of kinematics or programming
tools, we always strive to standardise the use,
programming and settings of different products.
Every machining operation, whether whirling
external and internal threads, tangential thread
milling, gear hobbing, drilling deep bores at high
pressure of up to 340 bar, stamping, the realisa-
tion of complex forms by HSM milling (i.e. milling
of Torx, milling by polar coordinates), is pos-
sible on virtually all the products we offer (single
spindle and multispindle). These operations are
also possible during a counter operation (second
spindle), which very often means that machin-
ing times for each operation at the bar and in
counter operation are evenly distributed and
well-balanced which in turn improves productiv-
ity. Machining times are shortened considerably,
despite the extreme complexity of some parts.
We also base our everyday operations on this
idea of real productivity in order to remain one
step ahead of the competition and offer solutions
which are perfectly suited to each requirement.
The flexible configuration of our machining cent-
ers can precisely be adapted to your needs no
matter how demanding they can be. We can,
for example, refer to the experience we have
acquired in the machining of hard ceramic with
machine elements and protections in stainless
steel (CU 1007).
A tried and tested concept
Every one of your developments undergoes a
tough validation process at every stage of the
manufacturing and industrialisation process,
whatever the level of integration envisaged for
the final product. This process involves taking
several different parameters and their implica-
tions into account.
A TRIED AND TESTED CONCEPT
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6 Medical
A SOLUTION FOR EVERY TYPE OF PART
Example : maxillofacial screws, micro screws and dental implants
Example : trauma and orthopaedic screws with complex dental
implants and abutments
Example : trauma orthopaedic and spine (mono and poly axial)
screws, nails, hip screws.
Maxillofacial screws
Humeral locking screws
Schanz screws
Guide wires
Dental implants
Dental abutments
Caps / screws Drill / reamers
Sleeves / connectors
Bone screws
Cannulated / corticalis screws Corticalis / malleolar screws
Humeral locking screws
Locking screws
Trocar
Connecting rods
Drill sleeves
Distraction / compression rods
Dental implants
Angled abutments
Drill / reamers
Cannulated screws
Nails
Lag / hip screws
Mono / poly axial screws
Spine hooks
Poly axial heads
Connecting rods
Tooling Nuts
EvoDECO 10a / 10e
EvoDECO 16a / 16e
DECO 20a / 20e / 26a / 26e
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7Medical
FOR MACHINING YOUR PARTS WITHOUT
SECONDARY OPERATION
Example : screws for implants, covers, simple abutments.
Bone screws
Locking screws
Corticalis screws
Connecting rods
Nails
Nuts
Tooling
Sigma 20 / 32
Gamma 20
Delta 12 / 20 Micro 7 / 8
Example : screws for implants, covers, simple abutments.
Bone screws
Dental implants Abutments
Tooling
Dental abutments
Caps / screws
Sleeves / connectors
Dental abutments
Caps / screws
Sleeves / connectors
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9Medical
MultiSigma 8x28
Simple counter operations
MultiAlpha 8x28 / MultiAlpha 6x32
Complex counter operations
Example : orthopaedic nut, screw
Example : Poly axial head, orthopaedic nut, screw
Bone screws
Implants
Polyaxial heads (spine)
Bone screws
Implants
FOR MACHINING YOUR PARTS WITHOUT
SECONDARY OPERATION
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10 Medical
SOLUTION PROVIDER
Chip conveyors
Bar-feeders
High pressure pumps
Machining andprocessing
Oil and air filters
Burring
Manipulating
Pallettising
Part-feeders
Cleaning
Partsmeasurements
Robotisation
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12 Medical
PRODUCTS PERFECTLY SUITED
TO YOUR REQUIREMENTS
Products perfectly suited to your
requirements We are experts in complex machining
processes.
We develop software functions for machining
complex shapes.
We design equipment which is specific to your
own production requirements.
We develop specific cutting tools and other
tooling in close collaboration with partners
skilled in the field.
We can offer peripheral equipment perfectly
suited to your needs (safety, handling, measur-
ing, operator and environmental protection).
Tornos EvoDECO 16a
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13
T41
T53
T51
T42
T42
T43
T14
T24
T15
T12
T21
T31
T32
T33
T15
T13
T23
Medical
PRODUCTS PERFECTLY SUITED
TO YOUR REQUIREMENTS
Dental abutments (for implant) in titanium
Realization on Tornos EvoDECO 16a
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14
Z48
Y48S58
S18S17S16S15S14
S11S12S13
S48
X11
Z11
MS1 X12
Z12
X13
Z13
Z21
Z22
Z23
9.2
9.3
8
7
6
4
3
1
2
5
Medical
MACHINING SEQUENCE
Optimum productivity
We develop new machining processes on
multispindle turning machines to reach an
extremely high level of productivity.
For parts in the Medtech sector, we also
adapt multispindle products to be able to run
specific operations (e.g. thread-whirling
process, high pressure drilling, internal and
external micro-milling).
We adapt peripheral equipment (e.g. handling,
measuring, swarf processing) as well as all
other general client parameters which are key
to productivity.
Locking motorfor the barrel
Motor for rotating tools of thecounter-operations pos. 8
Counter-spindlemotor in pos. 8
Titanium 15,5 mm lg. 17,2 mm
Tornos MultiAlpha 8x28
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15Medical
MACHINING SEQUENCE
Tornos FB 1005 Milling center
Numerical B axis.
3 independent tooling systems
(steady and rotating).
Machining of PEEK.
Tornos FB 1005
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16 Medical
MEDICAL APPLICATIONS
Maxillofacial, orthopaedics, trauma, hip screws
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium Steel 316 L
Steel 316 L
Steel 316 LSteel 316 L
Titanium
Steel 316 L
Steel 316 L
Titanium Steel 316 L
Titanium
Titanium
Steel 316 L TitaniumSteel 316 LSteel 316 L
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18 Medical
MEDICAL APPLICATIONS
Tooling, components
Steel 316 L Titanium
Stainless Steel 304
Stainless Steel 304
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19Medical
MEDICAL APPLICATIONS
Implants /dental components
Titanium
Titanium
Titanium
Titanium
Stainless steel 316 L
Titanium
Titanium
Titanium
Titanium
Titanium
Stainless steel 316 L
Stainless steel 316 L
Stainless steel 316 L
Titanium
Stainless steel 316 L
Stainless steel 316 L
Titanium
Titanium Titanium Titanium
Zirconia Cobalt ChromeTitanium Titanium X5CrNiCuNb 16-4
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21
z
s
c
x
Medical
MACHINING TECHNOLOGY
Internal thread-whirling process
(main operations and counter operations)
Benefits of the process
Low cutting forces due to different cuttingedges and tool rotation speeds.
Superior general quality of finish compared to
standard threading processes.
Threading in a single cut.
Threads go in and come out "whole", no
tapered threads.
Perfect swarf control (fine particles) by virtue of
adapted cutting speed and cutting lubrication
on unit (pressure 20 bar).
Tool lifetime is extended and tools can be
resharpened (regular profiled blades / approx.
40-60 times possible resharpenings)
Machining technology with constant profile
cutting tools or inserts.
Cutting tools are pre-set before enteringmachine and rapid assembly / disassembly of
tool holder head.
Angling of the whirling head according to the
thread helix (up to 24 degrees).
Length of thread-whirling process up to
200 mm depending on type turning machine.
No burrs outside or inside threads.
External thread-whirling process at the bar and
in counter operation in 'masked time' mode.
Internal thread-whirling at the bar and in coun-
ter operation in 'masked time' mode.
Spindle 80000 rpm
Tool 1 mm
Principle diagram for internal thread-whirling process
Internal thread-whirling tool
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22 Medical
MACHINING TECHNOLOGY
Boring / drilling deep bores at high pressure 120 / 340 bar
Using a high pressure cutting liquid (up to
340 bar) for boring deep bores is often essen-tial to guarantee cost-effective and productive
machining of different components in
the Medtech sector (chamfered screws, hip
screws, tooling, etc.).
Many implants on the market require transverse
bores. In general, the ratio between the
drilling diameter and the length to be machined
is high (drilling length up to 50-60 x
the diameter), depending on shape of part.
The high pressure systems (from 120 to
340 bars) can be adapted on most our productline equipped with a standard interface and
the integration is possible on the entire line of
single and multispindle machines.
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23Medical
MACHINING TECHNOLOGY
Boring / drilling deep bores at high pressure 120 / 340 bar
Milling of the self tapping forms
To facilitate the implantation of the screw
into the bone mass, the implants must be self
tapping to ease the penetration.
Thanks to the use of specific attachments
and cutting tools, its possible to achieve
these operations, either in main operations
(at the bushing) or in counter operations.
The use of thread whirling process eliminate
any burrs resulting from the milling of the self
tapping features.
View of a screw about 120 mm long with the various pre-settable tools used to produce it.
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24 Medical
MACHINING TECHNOLOGY
Machining Torx shapes and other specific high-speed milling applications
Medical applications occasionally require mill-
ing / drilling with extremely small-sized tools.High-speed spindles are also key to achieving
optimum cutting parameters and the required
finishes.
High-frequency spindles enable rotation speeds
of up to 80000 rpm to be reached.
These operations can be carried out on the turn-
ing machines both as main operation and as
counter operation in 'masked time' mode.
The same high-frequency spindles are used for
internal thread-whirling operations and other
end / transverse operations which require high cut-
ting speeds.
Benefits
Perfect for use with small-sized tools. Can be adapted to suit all products in main
and counter operation.
Suitable for confined spaces.
Straightforward rotational speed setting
with potentiometer.
Cutting speed adapted for increased
productivity.
Suppression of microburrs thanks to
the high cutting speed and the use of small
cutting tools.
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25Medical
MACHINING TECHNOLOGY
Machining specific shapes with the stamping process
Some components especially for the spine,
orthopedic nails and dental implants, require
specific equipment to produce complex forms,
usually by milling.
Tornos is continually developing new options
which are suited to the needs of the customer.
Alongside this, we are also developing customer
specific macros to make the programming
of complex contours more straightforward.
Benefits
Machining highly complex parts without
secondary operation.
Straightforward programming of shapes with
specific macros (automatic calculations of axis
movements and incremental program steps).
Counter operations generally carried out in
masked time mode. Milling units are mechanically set for angular
tool positioning depending on part.
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26 Medical
MACHINING TECHNOLOGY
Simultaneous 5 axis machining
Available on our machining centers CU 1007
and FB10055 axis machining gives you the freedom to
quickly produce complex shapes on a single
machine. It is then possible to angularly position
the part on 2 axes so to effectively drill or mill
at different angles. It is also possible to do 5 axis
interpolation for deburring operations, as well
as milling complex forms with the help of the
continuous interpolation of the machines 5 axes.
Advantages
Machining of complex shapes. Possibility to angularly position the part.
Possibility to simultaneously interpolate
the 5 axes of the machining center. Reduces
to use of form tools.
Enables to work from barstock or blanks.
Significant gain of time, enables to machine
complex forms in one clamping.
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27Medical
PERIPHERALS
Wide range of peripherals available depending on market needs
Fire protection systems
Co2extinguishing is a clean solution which
enables production to be started up again imme-
diately.
Part conveyors
These conveyors can be integrated with other
part handling systems.
Coolant cooling or heating systems
The temperature regulators maintain the cuttingfluid at a constant temperature allowing for high
precision machining.
Swarf conveyors
2 swarf conveyor systems are offered.
A standard system and one with a drum type
filtration system.
6 axis robot
The integration of high performing
6 axis robot offers an unequaled
autonomy of movements.
Oil mist extractors / filters
The filters are available in three versions : mechan-ical filters (HEPA H13), electro-static filters,
mechanical adaptations for centralized systems.
Paper filtration
Enables to get an optimal
cleanliness and increases the
life span of the cutting oil.
Stainless coolant tank (Zirconia)
Stainless coolant tank with a 30 microns cartridge
filter. Capacity : 100 liters, output : 40 l / min.
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nMarch20
11T
ornos2011,allrightsreserved
cm
TORNOS S.A.
Rue Industrielle 111
CH - 2740 Moutier
Tel. +41 (0)32 494 44 44
Fax +41 (0)32 494 49 03
contact@tornos.com
www.tornos.com
TORNOS TECHNOLOGIESDEUTSCHLAND GmbH
Karlsruher Str. 38
D - 75179 Pforzheim
Tel. +49 (0)7231 / 910 70
Fax +49 (0)7231 / 910 750
contact@tornos.de
TORNOS TECHNOLOGIES
FRANCE
Bote postale 330
St-Pierre en Faucigny
F - 74807 La Roches / Foron Cedex
Tel. +33 (0)4 50 038 333
Fax +33 (0)4 50 038 907
contact@tornos.fr
TORNOS TECHNOLOGIES
IBERICA
Pol. Ind. El Congost
Avda. St Julia, 206 Nave 8
E - 08403 Granollers
Tel. +34 93 846 59 43
Fax +34 93 849 66 00
commercial.tti@tornos.com
TORNOS TECHNOLOGIES
ITALIA SRL
Via Cesare Pavese 21
I - 20090 Opera / MI
Tel. +39 02 57 68 15 01
Fax +39 02 57 68 15 230
italia.contact@tornos.com
TORNOS TECHNOLOGIES
UK LTD
Tornos House
Whitwick Business Park
Coalville
UK - Leicestershire LE67 4JQ
Tel. +44 (0) 1530 513100
Fax +44 (0) 1530 814212
sales@tornos.co.uk
TORNOS TECHNOLOGIES
(Shanghai) LTD
Hui Feng Creativity Garden
Feng Yu Building, 1-2F
No. 239, Xitai Rd, Xu Hui District
CN - Shanghai 200232
Tel. +86 21 6235 1235
Fax +86 21 6235 1938
china.contact@tornos.com
TORNOS S.A. THAILAND
REPRESENTATIVE OFFICE
Flat 1B, The U.N. Residence
27/28 Sukhumvit Soi 33
Bangkok 10110
Thailand
Tel. +66 2 662 3908
Fax +66 2 662 3910
thailand.contact@tornos.com
TORNOS TECHNOLOGIES
US CORPORATION
840 Parkview Boulevard
US - Lombard, IL 60148
Tel. +1 630 812 2040
Fax +1 630 812 2039
info-us@tornos.com
www.tornos.us
TORNOS BEIJING OFFICE
Rm.1706, Tower A
Dongyu Office Building
Jia #1 Shuguang Xili
Chaoyang District
CN - Beijing 100028
Tel. +86 10 5979 8583
Fax +86 10 5822 0483
beijing.contact@tornos.com
TORNOS TECHNOLOGIES
ASIA LTD
Unit 4, Ground Floor, Transport City
Building
1-7 Shing Wan Road
Tai Wai, Shatin
N.T., Hong Kong
Tel. +852 2691 2633
Fax +852 2691 2133
asiapacific.contact@tornos.com
TORNOS TECHNOLOGIES ASIA LTD
MALAYSIA
REPRESENTATIVE OFFICE
K-7-1, Lorong Bayan Indah Dua,
Bay Avenue, 11900 Pulau Pinang,
Penang, Malaysia
Tel. +6 04 642 6562 / 642 6563
Fax +6 04 642 6561
malaysia.contact@tornos.com
TORNOS TECHNOLOGIES
POLAND Sp. z o.o.Ul. Brukselska 44 lok. 21A
PL - 03-973 Warszawa
Poland
Tel. +48 226 72 91 81
Fax +48 226 16 55 81
poland.contact@tornos.com
TORNOS DO BRASIL, Ltda
Av. Dr. Cardoso de Melo,
1470 Conj. 604
BR - 04548-004 Vila Olmpia
So Paulo - Brasil
Tel. +55 11 3045 6695
brazil.contact@tornos.com
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