1. Background introduction

In the medical field, the host front shell is an important device of the extracorporeal membrane oxygenation system and has strict material and processing requirements. This case study shows the company's successful experience in using 4-axis CNC to machine the host front shell. AL6061-T651 has high strength, corrosion resistance, light weight and excellent processing performance, making it the material of choice for many high-demand projects.

2. Material and technical challenges

1. The main processing challenges of AL6061-T651 include:

2. Work hardening: Work hardening occurs during cold processing, increasing processing difficulty and tool wear.

3. Insufficient high temperature performance: In high temperature (150°C) environment, the strength decreases significantly.

4. Stress corrosion cracking: Under the combined effect of corrosive environment and stress, the material may experience stress and corrosion cracking.

5. Dimensional stability: The drawing tolerance requirements are small and the structure is complex and the material stress may cause dimensional stability.

6. Surface treatment uniformity: The surface may be uneven or have color difference and when anodizing, some positions must meet the conductivity requirements.

7. High salt spray requirements: The salt spray requirements are high (96H, 10 levels), and the salt spray may not meet the requirements.

8. Parts interoperability: The requirements for each component to interoperate are high (the difference/gap is less than 0.1MM), and assembly interference or difference and gap may occur.

9. Cost control: The production and processing costs of this type of material are high.

10. Therefore, processing such parts requires high-precision equipment and strict process control. 4-axis CNC machine tools can provide advantages in these aspects, including reducing the errors caused by multiple clamping and being able to complete the processing of complex curved surfaces in one go.

3. Advantages of 4-axis CNC machining

1. Shiyuxiang Precision uses advanced 4-axis CNC machining, the main advantages include:

2. Improve machining efficiency: 4-axis CNC machining can perform multi-faceted machining at the same time, reduce tool change and adjustment time, and improve machining efficiency.

3. Improve surface quality: The surface treatment requirements of the front shell of this host are relatively high. Using 4-axis machining can reduce the knife marks and improve the surface quality through continuous cutting.

4. Enhance machining flexibility: The front shell structure of this host is relatively complex and the product is too large. Using 4-axis machining can handle the machining requirements of different angles and oversized products.

5. High precision: Using 4 axes can complete the machining of complex geometric shapes without multiple repositioning of parts, which significantly improves machining accuracy.

6. Reduce the number of clamping times: All-round machining can be completed in one clamping, which reduces the time of repeated positioning, improves machining efficiency and reduces potential errors.

7. Reduce costs: Using 4-axis machining can reduce production costs by reducing the number of clamping times, improving efficiency and reducing scrap rates.

4. Processing process

In order to ensure the accuracy and surface quality of the mainframe front shell, Shiyuxiang Precision follows the following processing steps:

1. Design and programming: According to the 2D and 3D drawings provided by the customer, Shiyuxiang Precision's engineering team programs the processing path of the parts in detail, especially the curved surface part, to ensure the consistency of the processing path with the design.

2. Roughing and finishing: Use 4-axis CNC machining for roughing to remove most of the material, and then perform finishing to ensure the required dimensional accuracy and surface finish.

3. Surface treatment: In order to meet the strict requirements of medical devices, the mainframe front shell is surface treated after processing, such as grinding, sandblasting and oxidation, to ensure that its surface is smooth and defect-free.

5. Quality control

In the production of medical devices, quality inspection is crucial. In order to ensure the various performances of the mainframe front shell, Shiyuxiang Precision implements the following quality control measures: Dimension detection: Use a high-precision three-coordinate measuring machine (CMM) to detect the key dimensions of the mainframe front shell to ensure that it meets the design tolerance requirements.

Surface quality inspection: Visually inspect the surface for burrs, cracks, steps, three scratches, uniform color, or other defects that may affect product safety.

Salt spray performance test: Salt spray test the finished product to ensure its corrosion resistance in actual use.

Conductive performance test: Conductive test the shielding area and laser engraving area of the finished product.

6. Compliance requirements in the medical industry

As a medical device, the production of the host front shell must meet strict industry standards. Shiyuxiang Precision also has the ISO 13485:2016 medical device quality management system certification. Shiyuxiang Precision strictly follows the ISO 13485:2016 medical device quality management system to ensure that every link from material procurement, processing to testing meets the standards. In addition, the host front shell must pass a series of performance tests to ensure its safety and stability in use.

7. Conclusion

Through this case study, it can be seen that Shiyuxiang Precision successfully used 4-axis CNC technology to solve the difficulties in the processing of the host front shell, ensuring high standards in terms of processing stability, flexibility and surface quality of the host front shell. This case not only demonstrates Shiyuxiang Precision's technical strength in difficult processing, but also shows that it has excellent experience and capabilities in the field of medical device manufacturing, providing customers with products that meet the strict requirements of the medical industry. It also highlights Shiyuxiang Precision's innovative ability in the medical field and its advantages in providing customized high-precision component solutions.