MILLSTAR USA Quad Force Machining a Knee Replacement Ti 6AL4V

The latest advancement in medical device manufacturing is quad force machining. Adopting this productivity boosting process removes time and tooling costs in manufacturing of most Titanium, cobalt chrome and stainless steel parts. To properly apply the quad force machining philosophy, part geometry must be divided into high feed and side milling operations including Trochoidal. The video is a typical Knee implant machined from Titanium 6Al4V.

Operation 1 (QFM Rough Side Mill)
Material: titanium 6Al4V
Cutting Tool: QFM-0500-HSN
Spindle Speed: 5200 RPM
Feed Rate: 154 IPM
Depth of Cut: 0.750”
Width of Cut: 0.016”
Metal Removal Rate: 1.848

Operation 2 (QFM High Feed Machining)
Material: titanium 6Al4V
Cutting Tool: QFM-0500-HSN
Spindle Speed: 5200 RPM
Feed Rate: 154 IPM
Depth of Cut: 0.016”
Width of Cut: 0.300”
Metal Removal Rate: 0.739

Operation 3 (QFM Side Mill Finishing)
Material: titanium 6Al4V
Cutting Tool: QFM-0500-HSN
Spindle Speed: 5200 RPM
Feed Rate: 154 IPM
Depth of Cut: 0.750”
Width of Cut: 0.005”

Operation 4 (True 4 flue ball nose finishing)
Material: titanium 6Al4V
Cutting Tool: BI4T-0375-HSN
Spindle Speed: 6621 RPM
Feed Rate: 132 IPM
Depth of Cut: 0.0054”
Width of Cut: 0.0054”