Titanium alloy artificial cochlea laser cutting integrated forming machining method

Abstract

The invention relates to the technical field of titanium alloy artificial cochlea machining, in particular to a titanium alloy artificial cochlea laser cutting integrated forming machining method. According to the method, precise cutting can be achieved at the micron level through the laser cutting technology, the size precision and shape stability of the titanium alloy artificial cochlea are ensured, compared with a traditional machining method, laser cutting can greatly improve the production efficiency, a heat affected zone generated in the laser cutting process is small, the surface quality of materials can be effectively kept, and the quality of the titanium alloy artificial cochlea is improved. According to the artificial cochlea, thermal deformation or non-uniform surface roughness is avoided, so that the use comfort and durability of the artificial cochlea are improved, laser cutting has an efficient material utilization rate, almost no redundant waste is generated in the cutting process, the material cost is reduced, accurate cutting also reduces rework required by dimensional deviation, and the production efficiency is improved. The material loss in the production process is further reduced, multiple procedures are reduced, and the overall production efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of titanium alloy cochlear implant processing, and in particular to a titanium alloy cochlear implant laser cutting integrated molding processing method. Background Art

[0002] With the continuous development of science and technology, cochlear implants, as an important hearing rehabilitation device, are widely used in patients with hearing impairment due to hearing loss or ear diseases. Cochlear implants convert sound signals into nerve signals through electrical stimulation and transmit them to the brain to help patients recover some of their hearing. However, the design and manufacturing process of cochlear implants is extremely complex, especially its core structure, which requires high precision while also having extremely high biocompatibility and stability.

[0003] Titanium alloy, as a material with excellent biocompatibility, mechanical strength and corrosion resistance, has become an ideal choice for cochlear implant manufacturing. Titanium alloy materials can not only withstand the test of long-term physiological environment, but also have low weight and good processing performance, which can effectively improve the comfort and service life of cochlear implants. However, due to the high processing hardness and toughness of titanium alloy, its processing process faces a series of challenges.

[0004] Traditional titanium alloy processing methods usually rely on machining, turning, milling and other technologies, but these methods not only have low processing efficiency, but also make it difficult to ensure the integrity and accuracy of the materials during processing, which can easily lead to large dimensional deviations of components and even affect the performance and use of components. No solutions have been proposed for related technical problems. Summary of the invention

[0005] In view of the problems in the related art, the present invention proposes a titanium alloy cochlear implant laser cutting integrated molding processing method to overcome the above technical problems existing in the existing related technology. The purpose of the present invention is to accurately control the focus and energy density of the laser to perform high-precision cutting at the micron level, with high processing efficiency and excellent surface quality, to ensure high precision, high quality and high consistency of the parts, to achieve cutting of complex structures, to reduce the steps required for multiple processes in traditional processing, and to simplify the processing flow.

[0006] To achieve the above object, the present invention provides the following technical solution: a titanium alloy cochlear implant laser cutting integrated molding processing method, comprising the following steps:

[0007] S1. Operation preparation: Take corresponding protective measures in each step. Production environment records are required before production, and operators must wear the required equipment according to the workshop requirements.

[0008] S2. Material preparation: Select TC4 bar with diameter of φ4±0.01 and provide corresponding material report to ensure that the material meets the requirements;

[0009] S3, Turning: Turning the material, including outer contour processing and inner hole contour processing;

[0010] S4. Tooling and fixture processing: Process the tooling according to the requirements of the femtosecond fixture to ensure that the fixture clamping error is less than 0.01mm, and verify the runout and repeated positioning accuracy of the components after clamping;

[0011] S5, Femtosecond processing: Femtosecond laser processing of components;

[0012] S6. Grinding and polishing: Use nickel-titanium wire for cross-grinding to ensure the stability and accuracy of the parts during polishing. Use compressed air for uniform polishing and use a microscope to check the polishing effect to avoid over-polishing or omissions.

[0013] S7, cleaning;

[0014] S8. Cleaning and storage: Clean and dry the finished parts, place them in material boxes, and store them separately to prevent extrusion and deformation.

[0015] Preferably, S3 includes:

[0016] (1) Finishing of the smooth end surface: Use a 15° external circular cutter, a speed of S1500, and a feed rate of 0.02 mm / min;

[0017] (2) Center hole processing: speed is S1500, feed rate is 0.02 mm / min;

[0018] (3) Punching: φ1.0 hole, depth 0.95 mm, speed S1000, feed rate 0.015 mm / min;

[0019] (4) Inner hole processing: φ1.2 hole, depth 1.0 mm, roughing with cobalt collar 0.8 boring tool cycle instruction, finishing speed S2000, feed rate 0.005 mm / min;

[0020] (5) Outer diameter processing: Use a 15° external cylindrical cutter to process φ1.55, φ1.62, and φ3.1 outer diameters. The speed is S1500 and the feed rate is 0.007 mm / min.

[0021] Preferably, the step S5 specifically includes the following steps:

[0022] (1) Use the reference point on the tooling to debug the reference point during the processing and set it as the zero point;

[0023] (2) Adjust the focal length of the femtosecond laser and set appropriate laser processing parameters to ensure processing accuracy;

[0024] (3) Adjust the femtosecond laser processing parameters: frequency is 200 kHz, pulse width is 350 fs, laser energy is 20 μJ, laser power is 4 W, shielding gas flow rate is 30 L / min, laser scanning speed is 2000 mm / s, laser spot diameter is 35 μm, and processing times is 2400.

[0025] Preferably, in S5, during femtosecond laser processing, the laser scanning path is optimized according to the drawing to improve processing accuracy and processing efficiency.

[0026] Preferably, in S6, the abrasive used in the grinding and polishing process is pierc4500, and the abrasive speed is set to 30 rpm to ensure a smooth surface with a reflective effect.

[0027] Preferably, in S7, an ultrasonic cleaning machine is used for cleaning, and the cleaning liquid used is a solution containing 70% alcohol, and the cleaning time is 15 minutes, so as to ensure that any impurities and dust before cleaning are completely removed.

[0028] Preferably, the dimensional accuracy of the parts shall be checked by a high-power microscope after turning, femtosecond machining and grinding and polishing, and ensured to meet the dimensional requirements of the drawings, with the deviation controlled within ±0.01mm.

[0029] Preferably, in S5, after femtosecond processing, the workpiece is calibrated and clamped repeatedly for multiple times to ensure that the accumulation of errors during the processing is minimized.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] (1) The present invention is a titanium alloy cochlear implant laser cutting integrated molding processing method. By recording the production environment and wearing appropriate protective equipment, the safety of operators can be ensured, unnecessary accidents can be avoided during the production process, and work efficiency and product quality can be improved. The selection of TC4 materials that meet the standards can ensure that the quality of parts meets the requirements, ensure the smooth progress of subsequent processing links, and avoid processing problems or unstable quality caused by unqualified materials. Turning can accurately process the outer contour and inner hole contour, ensure that the size and shape of the parts meet the design requirements, and through reasonable selection of processing parameters, effectively improve the processing accuracy and ensure the consistency and reliability of the product.

[0032] (2) The present invention is a titanium alloy cochlear implant laser cutting integrated molding processing method, which ensures that the tooling fixture matches the femtosecond fixture, and the clamping error is less than 0.01mm, which can effectively reduce the error in the clamping process, ensure the precise positioning of the parts during the processing, improve the repeatability and accuracy of the processing, and use femtosecond laser to process the fine bottom fan shape and opening position to ensure high processing accuracy. Laser processing can reduce the error of traditional mechanical processing and avoid deformation and damage. Through precise laser parameter setting, consistent processing quality can be obtained in each processing cycle;

[0033] (3) The present invention is a method for laser cutting and integrated molding of a titanium alloy cochlear implant. Through a fine polishing process, the surface of the parts is ensured to be smooth and uniform, and surface damage or over-polishing is avoided, thereby improving the appearance quality of the product and the surface reflective effect, thereby meeting high surface quality standards. Ultrasonic cleaning is used to effectively remove residual impurities, polishing dust and other pollutants, thereby ensuring the cleanliness of the product and avoiding the impact of pollutants on subsequent operations or uses, thereby improving the quality and stability of the product. After cleaning, the parts are dried and stored in a special material box, which can effectively prevent deformation or damage of the parts during storage, thereby ensuring that the product remains in good condition during subsequent production links or transportation. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 The figure is a flow chart of the processing method of the present invention. DETAILED DESCRIPTION

[0035] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0036] Example 1

[0037] See also Figure 1 The present invention proposes a technical solution for a titanium alloy cochlear implant laser cutting and integrated molding processing method: a titanium alloy cochlear implant laser cutting and integrated molding processing method, comprising the following steps:

[0038] S1. Operation preparation: Take corresponding protective measures in each step. Production environment records are required before production, and operators must wear the required equipment according to the workshop requirements.

[0039] S2. Material preparation: Select TC4 bar with diameter of φ4±0.01 and provide corresponding material report to ensure that the material meets the requirements;

[0040] S3, Turning: Turning of materials, including outer contour processing and inner hole contour processing; specifically, including:

[0041] (1) Finishing of the smooth end surface: Use a 15° external circular cutter, a speed of S1500, and a feed rate of 0.02 mm / min;

[0042] (2) Center hole processing: speed is S1500, feed rate is 0.02 mm / min;

[0043] (3) Punching: φ1.0 hole, depth 0.95 mm, speed S1000, feed rate 0.015 mm / min;

[0044] (4) Inner hole processing: φ1.2 hole, depth 1.0 mm, roughing with cobalt collar 0.8 boring tool cycle instruction, finishing speed S2000, feed rate 0.005 mm / min;

[0045] (5) Outer diameter processing: Use a 15° external cylindrical cutter to process φ1.55, φ1.62, and φ3.1 outer diameters, with a speed of S1500 and a feed rate of 0.007 mm / min;

[0046] S4. Tooling and fixture processing: Process the tooling according to the requirements of the femtosecond fixture to ensure that the fixture clamping error is less than 0.01mm, and verify the runout and repeated positioning accuracy of the components after clamping;

[0047] S5, femtosecond processing: performing femtosecond laser processing on the component; specifically, S5 includes the following steps:

[0048] (1) Use the reference point on the tooling to debug the reference point during the processing and set it as the zero point;

[0049] (2) Adjust the focal length of the femtosecond laser and set appropriate laser processing parameters to ensure processing accuracy;

[0050] (3) Adjust the femtosecond laser processing parameters: frequency is 200kHz, pulse width is 350fs, laser energy is 20μJ, laser power is 4W, shielding gas flow is 30L / min, laser scanning speed is 2000mm / s, laser spot diameter is 35μm, and processing times is 2400; during femtosecond laser processing, the laser scanning path is optimized according to the drawing to improve processing accuracy and efficiency; after femtosecond processing, the workpiece is calibrated and clamped repeatedly to ensure that the accumulation of errors during the processing is minimized;

[0051] S6. Grinding and polishing: Use nickel-titanium wire for cross-grinding to ensure the stability and accuracy of the parts during polishing. Use compressed air for uniform polishing and use a microscope to check the polishing effect to avoid over-polishing or omissions. Specifically, the abrasive used in the grinding and polishing process is pierc4500, and the abrasive speed is set at 30 rpm to ensure a smooth surface with a reflective effect.

[0052] S7. Cleaning: Specifically, use an ultrasonic cleaning machine for cleaning, and the cleaning solution used is a solution containing 70% alcohol. The cleaning time is 15 minutes to ensure that any impurities and dust before cleaning are completely removed;

[0053] S8. Cleaning and storage: Clean and dry the finished parts, place them in material boxes, and store them separately to prevent extrusion and deformation.

[0054] In this embodiment, the dimensional accuracy of the components must be checked by a high-power microscope after turning, femtosecond machining, and grinding and polishing to ensure that they meet the dimensional requirements of the drawings and the deviation is controlled within ±0.01mm.

[0055] The present invention can ensure the safety of operators and avoid unnecessary accidents in the production process by recording the production environment and wearing appropriate protective equipment, while improving work efficiency and product quality; the selection of TC4 materials that meet the standards can ensure that the quality of parts meets the requirements, ensure the smooth progress of subsequent processing links, and avoid processing problems or unstable quality caused by unqualified materials; turning can accurately process the outer contour and inner hole contour, ensure that the size and shape of the parts meet the design requirements, and effectively improve the processing accuracy through reasonable selection of processing parameters to ensure the consistency and reliability of the product; ensure that the tooling fixture matches the femtosecond fixture, and the clamping error is less than 0.01mm, which can effectively reduce the errors in the clamping process, ensure the precise positioning of parts in the processing process, improve the repeatability and accuracy of processing, and use femtosecond laser processing. The fine bottom fan shape and opening position ensure high processing accuracy. Laser processing can reduce the errors of traditional mechanical processing and avoid deformation and damage. Through precise laser parameter settings, consistent processing quality can be obtained in each processing cycle; through fine polishing process, the surface of parts is ensured to be smooth and uniform, and surface damage or over-polishing is avoided, which improves the appearance quality of the product, improves the surface reflective effect, and meets high-demand surface quality standards; through ultrasonic cleaning, residual impurities, polishing dust and other contaminants are effectively removed to ensure product cleanliness, avoid the impact of contaminants on subsequent operations or use, and improve the quality and stability of the product; after cleaning, drying and storing in a special material box, it can effectively prevent the parts from deformation or damage during storage, and ensure that the product remains in good condition in subsequent production links or transportation.

[0056] In the description of the present invention, it is necessary to understand that the terms "coaxial", "bottom", "one end", "top", "middle", "the other end", "upper", "one side", "top", "inside", "front", "center", "both ends" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0057] In the present invention, unless otherwise clearly stipulated and limited, the terms such as "installation", "setting", "connection", "fixation" and "screw-on" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two elements or the interaction relationship between two elements. Unless otherwise clearly defined, ordinary technicians in this field can understand the specific meanings of the above terms in the present invention according to the specific circumstances.

[0058] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A titanium alloy cochlear implant laser cutting integrated molding processing method, characterized in that: The following steps are involved: S1. Operation preparation: Take corresponding protective measures in each step. Production environment records are required before production, and operators must wear the required equipment according to the workshop requirements. S2. Material preparation: Select TC4 bar with diameter of φ4±0.01 and provide corresponding material report to ensure that the material meets the requirements; S3, Turning: Turning the material, including outer contour processing and inner hole contour processing; S4. Tooling and fixture processing: Process the tooling according to the requirements of the femtosecond fixture to ensure that the fixture clamping error is less than 0.01mm, and verify the runout and repeated positioning accuracy of the components after clamping; S5, Femtosecond processing: Femtosecond laser processing of components; S6. Grinding and polishing: Use nickel-titanium wire for cross-grinding to ensure the stability and accuracy of the parts during polishing. Use compressed air for uniform polishing and use a microscope to check the polishing effect to avoid over-polishing or omissions. S7, cleaning; S8. Cleaning and storage: Clean and dry the finished parts, place them in material boxes, and store them separately to prevent extrusion and deformation.

2. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 1, characterized in that: The S3 includes: (1) Finishing of the smooth end surface: Use a 15° external circular cutter, a speed of S1500, and a feed rate of 0.02 mm / min; (2) Center hole processing: speed is S1500, feed rate is 0.02 mm / min; (3) Punching: φ1.0 hole, depth 0.95 mm, speed S1000, feed rate 0.015 mm / min; (4) Inner hole processing: φ1.2 hole, depth 1.0 mm, roughing with cobalt collar 0.8 boring tool cycle instruction, finishing speed S2000, feed rate 0.005 mm / min; (5) Outer diameter processing: Use a 15° external cylindrical cutter to process φ1.55, φ1.62, and φ3.1 outer diameters. The speed is S1500 and the feed rate is 0.007 mm / min.

3. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 1, characterized in that: The S5 specifically includes the following steps: (1) Use the reference point on the tooling to debug the reference point during the processing and set it as the zero point; (2) Adjust the focal length of the femtosecond laser and set appropriate laser processing parameters to ensure processing accuracy; (3) Adjust the femtosecond laser processing parameters: frequency is 200 kHz, pulse width is 350 fs, laser energy is 20 μJ, laser power is 4 W, shielding gas flow rate is 30 L / min, laser scanning speed is 2000 mm / s, laser spot diameter is 35 μm, and processing times is 2400.

4. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 3, characterized in that: In S5, during femtosecond laser processing, the laser scanning path is optimized and set according to the drawing to improve processing accuracy and processing efficiency.

5. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 1, characterized in that: In the S6, the abrasive used in the grinding and polishing process is pierc4500, and the abrasive speed is set to 30 rpm to ensure a smooth surface with a reflective effect.

6. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 1, characterized in that: In S7, an ultrasonic cleaning machine is used for cleaning, and the cleaning liquid used is a solution containing 70% alcohol. The cleaning time is 15 minutes to ensure that any impurities and dust before cleaning are completely removed.

7. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 1, characterized in that: The dimensional accuracy of the parts must be checked under a high-power microscope after turning, femtosecond processing, grinding and polishing, and ensure that they meet the dimensional requirements of the drawings, with the deviation controlled within ±0.01mm.

8. The method for laser cutting and integrally forming a titanium alloy cochlear implant according to claim 1, characterized in that: In S5, after femtosecond processing, the workpiece is calibrated and clamped repeatedly for multiple times to ensure that the accumulation of errors during the processing is minimized.

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