Method for producing an elongate component having a top face and a bottom face

Abstract

The invention relates to a method for producing an elongate component, in particular a connecting component, having a top face and a bottom face, the method comprising the steps of: - clamping a blank (10), which has, in particular, a planar basic shape and is to be machined, in a first clamp, in particular in a horizontal orientation; - machining the blank (10) in the first orientation to expose surfaces representing at least the top and the bottom face of the component to be produced using a first machining tool (40) to form an intermediate component (20); - separating the intermediate component (20) from the remaining blank (10).

Description

[0001] Method for producing an elongated component having a top and a bottom side

[0002] The invention relates to a method for producing an elongated component having an upper and a lower side.

[0003] Corresponding methods for producing an elongated component having a top and a bottom side are known in the prior art in a variety of embodiments. In particular, these methods address the production of an elongated component having a top and a bottom side by machining, in particular milling, a blank.

[0004] Using appropriate processes, for example, connecting components can be manufactured to connect multiple objects or multiple object sections. Such connecting components can be medical devices. Specifically, such connecting components can be trauma implants, such as bone plates, which are used in cases of bone fractures.

[0005] Although corresponding connecting components can generally be produced with satisfactory results using known processes, there is a need for more advanced processes which are characterized in particular by higher efficiency in the production of corresponding connecting components.

[0006] The invention is based on the object of providing an improved method for producing a connecting component.

[0007] The object is achieved by a method for producing an elongated component having a top and a bottom side according to independent claim 1. The dependent claims relate to possible embodiments of the method according to independent claim 1.

[0008] A first aspect of the invention relates to a method for producing an elongated component having a top and a bottom side. The steps of the method explained in detail below thus result in the production of an elongated component having a top and a bottom side. The component is in particular a connecting component which is configured to connect a plurality of objects or a plurality of object sections of an object or a plurality of objects. A corresponding connecting component can have one or more interfaces, such as bores which can be penetrated by a fastening element, for example a screw and which are optionally provided with a thread, via which the connecting component can be fastened directly or indirectly to an object or object section. A corresponding connecting component can in particular be a medical component.Specifically, a corresponding connecting component can be a so-called trauma implant, such as a bone plate, which is used in the case of bone fractures.

[0009] Since, as will become apparent below, the method provides for machining, i.e. in particular milling, of a raw part (blank), the component is formed from a correspondingly machinable material. A corresponding material is typically a metal. Suitable metals are, in particular, iron-based metals, i.e. in particular steels, or titanium-based metals, i.e. in particular titanium alloys. Since, as mentioned, the component is, in particular, a medical-technical connecting component, such as in particular a bone plate, biocompatible metals are particularly suitable; the term "metal" used herein also includes metal alloys.

[0010] The blank described in more detail below, from which the component to be manufactured according to the process is to be cut out or peeled out, is formed from a machinable material analogously to the component to be manufactured or produced according to the process; the above explanations in connection with the component apply analogously.

[0011] A first step of the method involves clamping a blank to be machined, in particular one having a plate-like or plate-shaped basic shape, in a first clamping position, in particular in a horizontal orientation. In the first step of the method, a blank to be machined is thus clamped in a first clamping position, in particular in a horizontal orientation.

[0012] The blank typically has a plate-like or plate-shaped basic shape. Due to the plate-like or plate-shaped basic shape, the blank has a top side and a bottom side; the top and bottom sides typically equally form the main extension planes of the blank or are arranged parallel to at least one main extension plane of the blank. Due to the plate-like or plate-shaped basic shape, the blank also typically has a blank longitudinal axis; the blank longitudinal axis can extend within the at least one main extension plane of the blank or parallel to it.

[0013] The first clamping of the blank typically provides for the blank to be aligned horizontally with at least one main plane of extension. Thus, the top and bottom surfaces of the blank are typically arranged or aligned (essentially) parallel to a horizontal spatial plane in the first clamping; this further enables very efficient machining of the blank to produce the component using at least one machining tool.

[0014] The blank can already represent the basic shape of the component to be manufactured according to the method, at least in sections, and possibly completely. The basic shape of the blank can thus correspond to the basic shape of the component to be manufactured according to the method. If the basic shape of the component to be manufactured according to the method has, for example, curved sections, the blank can also have corresponding curved sections; this can considerably simplify the manufacture of the component. The blank can thus, for example, have one or more curved or angularly inclined sections, in particular with respect to a reference axis arranged parallel to the longitudinal axis of the blank, if the component to be freed or peeled out of the blank by machining also has one or more corresponding curved or angularly inclined sections.The top and / or bottom of the blank can thus have one or more curved or angularly inclined surface sections, particularly with respect to a reference axis arranged parallel to the blank's longitudinal axis. Since the blank typically has a uniform thickness or wall thickness, the top and bottom of the blank typically have curved or angularly inclined surface sections arranged parallel to one another.

[0015] The blank can also have at least one clamping section of the blank, onto which the active surfaces of one or more clamping elements of a clamping device can engage. After the machining or peeling out of an intermediate component from the blank, as explained below, the clamping section of the blank must be separated by a separation process in order to obtain the component.

[0016] The thickness or wall thickness of the blank is typically selected such that the blank can be clamped accordingly and subsequently machined using at least one machining tool without the risk of undesired deformations and vibrations occurring, in order to free or peel out the component to be manufactured according to the method by machining the blank. The thickness or wall thickness of the blank can specifically be in a range between 5 and 20 mm, in particular between 7.5 and 17.5 mm, furthermore in particular between 10 and 15 mm, furthermore in particular between 11 and 14 mm, furthermore in particular between 12 and 13 mm. Investigations have shown that these dimensions of the blank enable machining of the blank to free the component to be manufactured according to the method from the blank without the risk of undesired deformations and vibrations occurring.

[0017] The first step of the method can be carried out by means of a clamping device which is designed to clamp a blank to be machined, in particular one having a plate-like or -shaped basic shape, in a first clamping position, in particular in a horizontal orientation. For this purpose, the clamping device can comprise one or more clamping elements, such as clamping or chucking jaws, wherein at least one clamping element can be transferred into a clamping state in which a blank to be machined, in particular one having a plate-like or -shaped basic shape, can be clamped in a first clamping position, in particular in a horizontal orientation. The respective clamping elements can be arranged or aligned such that their respective active surfaces, with which they engage the blank, ie in particular a clamping section of the blank, are aligned horizontally.The clamping device can form a component of a machining device for machining a blank or can be assigned to such a machining device.

[0018] In a second step of the method, the blank is machined in the first orientation, which, as mentioned, is typically a horizontal orientation, in order to expose or peel out at least surfaces forming the top and bottom of the component to be produced by means of a first machining tool, thereby forming an intermediate component. In the second step of the method, a first machining tool, ie in particular a milling tool (milling cutter), further in particular a roughing or finishing cutter or a torus cutter, is moved along the blank clamped in the first clamping, whereby the blank is machined and, with it, an intermediate component is removed, which has surfaces forming at least the top and bottom of the component to be produced.Specifically, in the second step of the method, a first machining tool is moved along the top or bottom side of the blank clamped in the first setup, whereby the blank is machined and, concomitantly, an intermediate component is cut out, which has surfaces forming at least the top and bottom sides of the component to be manufactured. The intermediate component can be cut out of the blank by one or more machining operations; if multiple machining operations are implemented, at least a first machining operation can include contour milling and at least a second machining operation can include skiving, i.e., in particular, rotary skiving.

[0019] The intermediate component may have an oversize of less than 5 mm, in particular less than 3 mm, in particular less than 1 mm, relative to the final dimension of the component to be manufactured according to the method. The intermediate component may therefore have only a relatively small oversize relative to the final dimension of the component to be manufactured according to the method.

[0020] Alternatively, however, the intermediate component may already have the final dimension of the component to be manufactured according to the process. Thus, by appropriate machining of the blank, an intermediate component can be formed according to the process, which already has the final dimension of the component to be manufactured according to the process, so that after completion of the second step of the process, at least to achieve the final dimension of the component to be manufactured according to the process, no further machining of the intermediate component is required. From the above, it also follows that the process typically does not require any pre-machining of the blank, which could potentially have a negative impact on the properties of the component to be manufactured, i.e., in particular, its surface and dimensional accuracy.Apart from post-processing to adjust specific surface properties and / or to create appropriate interfaces, the component can then be completely cut or removed from the blank using the process. The blank machined in the second step of the process does not necessarily have to have a uniform oversize with regard to the final dimension of the component to be manufactured using the process, since uneven oversizes can also be taken into account during machining of the blank, particularly during the alignment and movement of the first machining tool.

[0021] During the second step of the method, the first machining tool is typically moved several times along the top and / or bottom of the blank clamped in the first setup, whereby it machines the blank. Movements of the first machining tool along the top or bottom of the blank clamped in the first setup typically occur in the direction of the blank's longitudinal axis along one or more movement paths, which extend, in particular, between a start point and an end point located on the top or bottom of the blank. A corresponding start point can be located in the region of a first free end of the top or bottom of the blank, and a corresponding end point can be located in the region of a second free end of the top or bottom of the blank opposite the first free end.Since typically a large part, if not the entire top and bottom of the blank is machined, the first machining tool is typically moved in several, in particular parallel, trajectories along the top of the blank and in several, in particular parallel, trajectories along the bottom of the blank. As mentioned, due to the clamping of the blank, the top or bottom of the blank is typically (essentially) aligned in or parallel to a horizontal spatial plane, which enables very efficient machining of the blank. Corresponding trajectories of the machining tool can be movements in one or more translational and / or rotational degrees of freedom along the or a surface of the blank clamped as described.Corresponding movements of the machining tool can therefore be combined movements in one or more translational and / or rotational degrees of freedom. Specifically, movements of the machining tool can include, for example, linear movements, trochoidal movements, or cycloidal movements of the machining tool. The above statements can apply to both the first machining tool and any additional machining tool.

[0022] Although the blank can be rotated or pivoted about a horizontal axis during machining, as will be explained below, it is typically not moved in the z-direction (vertical direction) during the entire machining process.

[0023] The movement of the first machining tool is based on a hardware and / or software-implemented motion control system. The motion control system can, in particular, include a 5-axis motion control system. The motion control system is typically based on geometric design data, i.e., in particular, dimensions, of the blank, the intermediate component, and the component to be manufactured according to the method. A corresponding control system is therefore particularly configured to generate corresponding movement paths of the first machining tool along the surface of the blank in order to expose or peel out the intermediate component. The hardware and / or software-implemented motion control system can, for example, be implemented by a CAM control system or as part of such a system.

[0024] The second step of the method can be carried out by means of a machining device comprising at least one first machining tool, i.e., in particular, a milling tool. The machining device can enable 5-axis machining of the blank. The machining device also typically comprises a corresponding hardware- and / or software-implemented control device, i.e., for example, a CAM controller or a part thereof, which is configured to implement hardware- and / or software-implemented movement control of the at least one machining tool. The control device is thus configured, in particular, to generate corresponding movement paths of the at least one machining tool along the surface of the blank.

[0025] In a third step of the process, the intermediate component is separated from the remaining, non-machined blank (section). Specifically, the intermediate component is separated from the aforementioned clamping section. The separation can be performed mechanically, for example, by cutting, sawing, etc.

[0026] The third step of the method can be carried out by means of a cutting device, which can be designed, for example, as a cutting or sawing device or can include such a device. The cutting device can also be a component of a corresponding machining device for machining the blank or be assigned to such a machining device.

[0027] The third step of the method can optionally be followed by at least one post-processing step, in which the exposed surfaces of the intermediate component are mechanically reworked to achieve the desired surface properties. This can apply in particular to the edge regions of the intermediate component, which can be reworked in a corresponding post-processing step, in particular to form a desired surface.

[0028] Alternatively or additionally, the third step of the method can optionally be followed by at least one post-processing step in which one or more interfaces, such as bores which can be penetrated by a fastening element, such as a screw, and which may be provided with a thread, are formed in the intermediate component. This can apply in particular to the top or bottom side of the intermediate component, which can be post-processed in a corresponding post-processing step, in particular to form corresponding interfaces, e.g. by drilling, threading, etc. The method can therefore generally include or comprise a processing step of introducing at least one interface, i.e. in particular a fastening interface, such as a bore, possibly a threaded bore, into the intermediate component or into the component.

[0029] The blank to be machined can, as indicated, be rotated or pivoted during machining. Accordingly, the first machining tool can expose an upper side (generally a first surface) of the component to be manufactured in at least one first rotation or pivot position of the blank, and can expose an underside (generally a second surface) of the component to be manufactured in at least one second rotation or pivot position, in particular a rotation or pivot position rotated by 180° relative to the first rotation or pivot position. In particular, the blank can be rotated or pivoted about a horizontally aligned rotation or pivot axis (b or y axis). By corresponding rotation orBy pivoting the blank, the described horizontally aligned clamping of the blank for exposing the intermediate component can be maintained (essentially) throughout the entire machining of the blank, which enables very efficient machining. The clamping device used to clamp the blank can therefore have a degree of freedom of rotational movement, which allows the blank to be machined to be rotated or pivoted accordingly during machining. The rotational or pivoting movements of the blank are typically coordinated or synchronized with movements of the first machining tool along the surface of the blank, in particular in such a way that the first machining tool can always be moved over a (essentially) horizontally aligned surface of the blank. This can be done, for example, byvia the control system mentioned above. The machining of the blank in the first orientation can also include or comprise the exposure of at least one surface, which represents a lateral edge region of the component to be manufactured according to the method, by means of the first machining tool. The lateral edge regions (side edges) forming the top and bottom of the component to be manufactured according to the method can thus also be machined by means of the first machining tool in order to impart the desired properties to them.

[0030] As mentioned, a roughing or finishing cutter, or a torus cutter, can be used as the first machining tool. Studies have shown that the process can be carried out particularly efficiently with these cutter types. All of the aforementioned cutters enable at least partial, or even complete, removal of the component to be manufactured from the blank ("from solid"). Torus cutters are particularly useful because, compared to ball-end cutters, they have a large number of cutting surfaces, which enables very efficient material removal.

[0031] The first machining tool can be moved at at least one oblique angle of incidence, in particular between 5 and 25°, relative to the respective surface of the blank to be machined, regardless of its specific configuration, i.e., in particular regardless of whether it is a roughing or finishing cutter or a torus cutter. A corresponding oblique orientation (position) of the first machining tool relative to the (essentially) horizontally oriented top or bottom side of the blank, as mentioned, can result in advantages with regard to material removal by machining. Furthermore, a corresponding oblique orientation (position) of the first machining tool can achieve certain surface properties.

[0032] In particular, the first machining tool can be moved at a plurality of different angles of attack relative to the surface of the blank to be machined, in particular such that the first machining tool is moved at a first angle of attack along a first section of the blank to be machined and at a second angle of attack along a second section of the blank to be machined, which section is oriented obliquely to the first section. By correspondingly changing the oblique orientation (angle of attack) of the first machining tool relative to the, as mentioned, (essentially) horizontally oriented top or bottom of the blank, advantages with regard to the material removal by machining can arise; this can apply in particular if the blank, as mentioned, is rotated or angled during machining. Consequently, the setting of corresponding angles of attack can be achieved with rotating orPivoting movements of the blank and movements of the first machining tool along the surface of the blank are coordinated or synchronized, in particular such that the first machining tool can always be moved over a (substantially) horizontally oriented surface of the blank. This can be achieved, for example, via the control system mentioned above.

[0033] At this point, it should be generally noted that any machining tool used in the process can be equipped with one or more cooling channels, which typically not only enables cooling of the respective machining tool but can also promote chip removal.

[0034] The method may further include or comprise a step of transferring the intermediate component into a second orientation and a step of machining the intermediate component in the second orientation to form desired surface properties of the intermediate component. The machining of the intermediate component in the second orientation typically occurs before the intermediate component is separated from the remaining blank (section), i.e., in particular, a corresponding clamping section. The second orientation may, for example, be an orientation inclined at an angle, in particular at a right angle, with respect to the horizontal orientation given in the first clamping.

[0035] The machining of the intermediate component in the second orientation can be performed using a second machining tool that is different from the first machining tool. A roughing or finishing milling cutter, for example, can be used as the second machining tool.

[0036] A second aspect of the invention relates to a machining device for producing an elongated component having a top and a bottom side, in particular a connecting component, further in particular a bone plate. The machining device comprises at least: at least one clamping device for clamping a blank to be machined, in particular having a plate-like or plate-shaped basic shape, at least in a first orientation; at least one machining tool for machining a blank clamped by means of the clamping device in the first orientation for exposing or peeling out at least surfaces representing the top and bottom sides of the or a component to be manufactured by means of the first machining tool, thereby forming an intermediate component; and a separating device for separating a correspondingly formed intermediate component from the remaining blank (section).Typically, the processing device also comprises a control device implemented in hardware and / or software, which is configured to control the operation of the processing device and the devices associated therewith.

[0037] The machining device is configured to carry out the method according to the first aspect of the invention, so that all statements relating to the method according to the first aspect apply analogously to the machining device, and vice versa. Accordingly, the clamping device can be configured to rotate or pivot a blank and to transfer an intermediate component, in particular by rotating or pivoting about a horizontal or vertical pivot axis, into at least one second orientation. In particular, the clamping device can be configured to transfer an intermediate component, in particular by rotating or pivoting about a horizontal rotation or pivot axis, into at least one second orientation, while the blank is being machined using the first machining tool.

[0038] The machining device can further comprise a second machining tool for machining the intermediate component in the at least one second orientation to form desired surface properties of the intermediate component. The second machining tool, although typically also a milling tool, is a machining tool configured differently from the first machining tool.

[0039] The first and / or second machining tool of the machining device can be a roughing or finishing milling cutter or a torus milling cutter.

[0040] The first machining tool can be positioned at at least one angle of attack relative to a surface of a blank to be machined, and can be moved relative to the surface of the blank being machined when positioned at the angle of attack. In particular, the first machining tool can be positioned at multiple angles of attack relative to the surface of the blank to be machined via a corresponding bearing, so that equal or unequal angles of attack can be achieved with corresponding rotational or pivoting movements of the blank during machining.

[0041] A third aspect of the invention relates to a hardware and / or software-implemented control device for a processing device, ie in particular for controlling the operation of a corresponding processing device, according to the second aspect of the invention, so that all statements in connection with the processing device according to the second aspect of the invention and with the method according to the first aspect of the invention apply analogously to the control device and vice versa.

[0042] The control device may be a computer program product comprising instructions that cause the processing device according to the second aspect of the invention to carry out the method according to the first aspect of the invention.

[0043] The control device, if implemented as a corresponding computer program product, may be stored on a computer-readable medium.

[0044] The invention is explained in more detail using exemplary embodiments in the drawing figures. In the drawings:

[0045] Fig. 1 , 2 each show a schematic diagram of a blank to be machined within the scope of a method according to an embodiment; and

[0046] Fig. 3 - 6 each show a schematic diagram of a second step of a method according to an embodiment.

[0047] With reference to the schematic diagrams shown in the figures, a method for producing an elongated component having a top and a bottom side is described below. The component is in particular a connecting component which is configured to connect a plurality of objects or a plurality of object sections of an object or a plurality of objects. A corresponding connecting component can have one or more interfaces (not shown), such as, for example, holes which can be penetrated by a fastening element, for example a screw, and which may be provided with a thread, via which the connecting component can be fastened directly or indirectly to an object or object section. A corresponding connecting component can in particular be a medical component. Specifically, a corresponding connecting component can be a so-called trauma implant, such as, for example,a bone plate, which is used for bone fractures.

[0048] Since, as will become apparent below, the method provides for machining, i.e. in particular milling, of a blank 10 shown in different perspective views in Figs. 1, 2, the component is formed from a correspondingly machinable material. A corresponding material is typically a metal. Suitable metals are, in particular, iron-based metals, i.e. in particular steels, or titanium-based metals, i.e. in particular titanium alloys. Since, as mentioned, the component is, in particular, a medical-technical connecting component, such as in particular a bone plate, biocompatible metals or metal alloys are, in particular, suitable.

[0049] The blank 10, from which the component to be manufactured according to the process is to be cut out or peeled out, is formed from a machinable material analogously to the component to be manufactured or produced according to the process; the above explanations in connection with the component apply analogously.

[0050] Figs. 1 and 2 indicate by means of corresponding hatching how the component to be produced or produced according to the method is positioned within the blank 10; the areas not hatched in Figs. 1 and 2 thus indicate the areas of the blank 10 which are to be removed by machining in order to expose or peel out the component from the blank 10.

[0051] A first step of the method provides for clamping the blank 10 to be machined, which has a plate-like or -shaped basic shape, as can be seen from Figs. 1 and 2, in a first clamping in a horizontal orientation. Figs. 3 - 6 show an example of a corresponding clamping situation. In the first step of the method, a blank 10 to be machined is therefore clamped in a first clamping in a horizontal orientation. Due to its plate-like or -shaped basic shape, the blank 10 has an upper side 11 and a lower side 12; the upper side 11 and the lower side 12 typically equally form the main extension planes of the blank 10 or are arranged parallel to at least one main extension plane 13 of the blank 10. Due to the plate-like or-shaped basic shape, the blank 10 also has a blank longitudinal axis L; the blank longitudinal axis L can extend within the at least one main extension plane 13 of the blank 10 or parallel to it.

[0052] From Figs. 3-6, it can be seen that the first clamping of the blank 10 provides that the blank 10 is aligned horizontally with at least one main extension plane 13. Thus, the top and bottom sides 11, 12 of the blank 10 are arranged or aligned (essentially) parallel to a horizontal spatial plane in the first clamping; this further enables very efficient machining of the blank 10 to produce the component using at least one machining tool 40.

[0053] 1 and 2 in particular, it can be seen that the blank 10 can already depict the basic shape of the component to be produced according to the method, at least in sections, and optionally completely. The basic shape of the blank 10 can therefore correspond to the basic shape of the component to be produced according to the method. If the basic shape of the component to be produced according to the method has curved sections, as shown by way of example in the figures, the blank 10 can also have corresponding curved sections; this can considerably simplify the production of the component. The blank 10 can therefore, for example, have one or more curved or angularly inclined sections, in particular with respect to a reference axis arranged parallel to the longitudinal axis L of the blank, even if the component to be released or peeled out of the blank 10 by machining also has one or more corresponding curved or angularly inclined sections.The top and / or bottom sides 11, 12 of the blank 10 can thus have one or more curved or angularly inclined surface sections 11', 12', in particular with respect to a reference axis arranged parallel to the blank's longitudinal axis. Since the blank 10 typically has a uniform thickness or wall thickness, the top and bottom sides 11, 12 of the blank 10 typically have curved or angularly inclined surface sections 11', 12' arranged parallel to one another.

[0054] Based on Figs. 3-6, which show the horizontally clamped blank 10 in a frontal view (cf. Figs. 3, 5) and in a top view (cf. Figs. 4, 6), it is evident that the blank 10 can also have at least one clamping section 14, onto which active surfaces 31, only schematically indicated in Fig. 3, of one or more clamping elements 30 of a clamping device (not shown in detail) can engage. After the machining or peeling out of an intermediate component 20 from the blank 10, as explained below, the clamping section 14 of the blank must be separated by a separation process in order to obtain the component.

[0055] The thickness or wall thickness of the blank 10 is selected such that the blank 10 can be clamped accordingly and subsequently machined using at least one machining tool without the risk of undesired deformations and vibrations occurring, in order to free or peel out the component to be manufactured according to the method by machining the blank 10. The thickness or wall thickness of the blank can specifically be, for example, in a range between 5 and 20 mm, in particular between 7.5 and 17.5 mm, furthermore in particular between 10 and 15 mm, furthermore in particular between 11 and 14 mm, furthermore in particular between 12 and 13 mm. Investigations have shown that these dimensions of the blank 10 enable machining of the blank 10 to free the component to be manufactured according to the method from the blank 10 without the risk of undesired deformations and vibrations occurring.The first step of the method can be carried out by means of a clamping device which is designed to clamp a blank 10 to be machined, having a plate-like or plate-shaped basic shape, in a first clamping in a horizontal orientation. For this purpose, the clamping device can comprise the aforementioned clamping elements 30, e.g. clamping or chucking jaws, wherein at least one clamping element 30 can be transferred into a clamped state in which the blank 10 to be machined can be clamped in a first clamping in a horizontal orientation. The respective clamping elements 30 can be arranged or aligned such that their respective active surfaces 31, with which they engage the blank 10, e.g. in particular the clamping section 14 of the blank 10, are aligned horizontally.The clamping device can form a component of a machining device for machining a blank 10 or can be assigned to such a machining device.

[0056] 3 - 6, the blank 10 is machined in the first orientation, which, as mentioned, is a horizontal orientation, in order to expose or peel out at least surfaces that form the top and bottom of the component to be produced by means of a first machining tool 40, thereby forming the aforementioned intermediate component 20. In the second step of the method, a first machining tool 40, ie in particular a milling tool (milling cutter), further in particular a roughing or finishing cutter or a torus cutter, is moved along the blank 10 clamped in the first clamping, wherein a machining of the blank 10 and, associated therewith, a removal of the intermediate component 20 takes place, which has surfaces that form at least the top and bottom of the component to be produced.Specifically, in the second step of the method, a first machining tool 40 is moved along the top or bottom side of the blank 10 clamped in the first setup, wherein a machining of the blank 10 and, concomitantly, a release of the intermediate component 20 takes place, which has surfaces forming at least the top and bottom sides of the component to be produced. The release of the intermediate component 20 from the blank 10 can take place by one or more machining operations; if several machining operations are to be implemented, at least a first machining operation can include contour milling as shown in Figs. 3, 4 and at least a second machining operation can include skiving as shown in Figs. 5, 6, ie in particular rotary skiving.

[0057] The intermediate component 20 can, as indicated in Fig. 3 by the border 21, have an oversize of less than 5 mm, in particular less than 3 mm, in particular less than 1 mm, with respect to the final dimension of the component to be produced according to the method. The intermediate component 20 can therefore only have a relatively small oversize with respect to the final dimension of the component to be produced according to the method.

[0058] Alternatively, however, the intermediate component 20 may already have the final dimension of the component to be manufactured according to the method; thus, according to the method, an intermediate component 20 can be formed by appropriate machining of the blank 10, which already has the final dimension of the component to be manufactured according to the method, so that after completion of the second step of the method, at least to realize the final dimension of the component to be manufactured according to the method, no further machining of the intermediate component 20 is required. From the above, it also follows that the method typically does not require any pre-machining of the blank 10, which could potentially have a negative effect on the properties of the component to be manufactured, i.e., in particular, its surface and dimensional accuracy.Apart from post-processing to adjust certain surface properties and / or to introduce corresponding interfaces, the component can thus be completely cut out or peeled out of the blank 10 according to the process.

[0059] The blank 10 machined in the second step of the method does not necessarily have to have a uniform allowance with regard to the final dimension of the component to be manufactured according to the method, since uneven allowances can also be taken into account during the machining of the blank 10, in particular during the alignment and movement of the first machining tool 40.

[0060] During the second step of the method, the first machining tool 40 is typically moved several times along the top and / or bottom side 11, 12 of the blank 10 clamped in the first setup, wherein it machines the blank 10. Movements of the first machining tool 40 along the top or bottom side 11, 12 of the blank 10 clamped in the first setup typically occur in the direction of the blank's longitudinal axis L along one or more movement paths, which extend, in particular, between a start point and an end point SP, EP located on the top or bottom side of the blank 10. A corresponding start point SP can be located in the region of a first free end of the top or bottom side 11, 12 of the blank 10, and a corresponding end point EP can be located in the region of a second free end of the top or bottom side 11, 12 of the blank 10, opposite the first free end.Since typically a large part of the top and bottom sides 11, 12 of the blank 10, if not the entire top and bottom sides 11, 12 of the blank 10, is machined, the first machining tool 40 is typically moved in several, in particular parallel, movement paths along the top side 11 of the blank 10 and in several, in particular parallel, movement paths along the bottom side 12 of the blank 10. As mentioned, the top and bottom sides 11, 12 of the blank are (substantially) aligned in or parallel to a horizontal spatial plane due to the clamping of the blank 10, which enables very efficient machining of the blank 10.

[0061] Movements of the machining tool 40 can be movements in one or more translational and / or rotational degrees of freedom along the or a surface of the blank clamped (essentially) horizontally as described. The first machining tool 40 can therefore be moved in the xy plane in one or more translational and / or rotational degrees of freedom along the or a surface of the blank clamped as described. Corresponding movements of the machining tool 40 can therefore be combined movements in one or more translational and / or rotational degrees of freedom. Specifically, movements of the machining tool can include, for example, linear movements, trochoidal movements or cycloidal movements of the machining tool 40. The above statements can apply both to the first machining tool 40 and to any additional machining tool.

[0062] Although the blank 10 can be rotated or pivoted about a horizontal axis during machining, as will be shown below in connection with Figs. 5 and 6, it is typically not moved in the z-direction (vertical direction) during the entire machining process.

[0063] The movement of the first machining tool 40 is based on a hardware and / or software-implemented motion control. The motion control can, in particular, include a 5-axis motion control. The motion control is typically based on geometric design data, i.e., in particular, dimensions, of the blank 10, the intermediate component 20, and the component to be produced according to the method. A corresponding controller is therefore, in particular, configured to generate corresponding movement paths of the first machining tool 40 along the surface of the blank 10 in order to expose or peel out the intermediate component 20. The hardware and / or software-implemented motion control can, for example, be implemented by a CAM controller or as part of such a controller.

[0064] The second step of the method can be carried out by means of a machining device (not shown) comprising at least one first machining tool 40, i.e., in particular, a milling tool. The machining device can enable 5-axis machining of the blank 10. The machining device also typically comprises a corresponding hardware- and / or software-implemented control device, i.e., for example, a CAM controller or a part thereof, which is configured to implement hardware- and / or software-implemented movement control of the at least one machining tool 40. The control device is thus configured, in particular, to generate corresponding movement paths of the at least one machining tool 40 along the surface of the blank.

[0065] Although the clamping arrangement shown by way of example in Fig. 4 is selected such that (essentially) rectilinear regions of the component to be produced are arranged on or at a side facing away from the clamping section 14, it is also possible in principle for such rectilinear regions of the component to be produced to be arranged on or at the side facing the clamping section 14; this can result in more efficient machining, particularly with regard to material consumption.

[0066] In a third step of the method, the intermediate component 20 is separated from the remaining, non-machined blank (section) 10. In particular, the intermediate component 20 is separated from the aforementioned clamping section 14. The separation can be performed mechanically, for example, by cutting, sawing, etc.

[0067] The third step of the method can be carried out by means of a separating device (not shown), which can be designed, for example, as a cutting or sawing device or can include such a device. The separating device can also form a component of a corresponding machining device for machining the blank 10 or be assigned to such a machining device.

[0068] The third step of the method may optionally be followed by at least one post-processing step, in which the exposed surfaces of the intermediate component 20 are mechanically reworked to achieve the desired surface properties. This may apply in particular to the edge regions of the intermediate component 20, which can be reworked in a corresponding post-processing step, in particular to form a desired surface.

[0069] Alternatively or additionally, the third step of the method can optionally be followed by at least one post-processing step in which one or more interfaces, such as bores which can be penetrated by a fastening element, such as a screw, and which may be provided with a thread, are formed in the intermediate component 20. This can apply in particular to the upper or lower side 11, 12 of the intermediate component 20, which can be post-processed in a corresponding post-processing step, in particular to form corresponding interfaces, e.g. by drilling, threading, etc. The method can therefore generally include or comprise a processing step of introducing at least one interface, ie in particular a fastening interface, such as a bore, optionally a threaded bore, into the intermediate component 20 or into the component.

[0070] The blank 10 to be machined can, as indicated by the arrows in Figs. 5 and 6, be rotated or pivoted during machining. Accordingly, the first machining tool 40 can expose an upper side 11 (generally a first surface) of the component to be produced in at least one first rotation or pivot position of the blank 10, and can expose an underside 12 (generally a second surface) of the component to be produced in at least one second rotation or pivot position, in particular a rotation or pivot position rotated by 180° relative to the first rotation or pivot position. In particular, the blank 10 can be rotated or tilted about a horizontally oriented rotation or pivot axis (b or y axis) emerging from the plane of the page. By appropriate rotation orBy pivoting the blank 10, the described horizontally oriented clamping of the blank 10 for the release of the intermediate component 20 can be maintained (essentially) throughout the entire machining of the blank 10, which enables very efficient machining. The clamping device used to clamp the blank 10 can therefore have a degree of freedom of rotational movement, which enables the blank 10 to be machined to be rotated or pivoted accordingly during the machining. The rotational or pivoting movements of the blank 10 are typically coordinated or synchronized with movements of the first machining tool 40 along the surface of the blank 10, in particular such that the first machining tool 40 can always be moved over a (essentially) horizontally oriented surface of the blank 10. This can be done, for example, bycan be realized via the control system mentioned above.

[0071] The machining of the blank 10 in the first orientation can also include or comprise the exposure of at least one surface, which represents a lateral edge region of the component to be produced according to the method, by means of the first machining tool 40. The lateral edge regions (side edges) forming the top and bottom of the component to be produced according to the method can thus also be machined by means of the first machining tool 40 in order to impart the desired properties to them.

[0072] As mentioned, a roughing or finishing milling cutter or a torus milling cutter shown in Figs. 5, 6 can be used as the first machining tool 40.

[0073] The first machining tool 40 can, as also evident from Figs. 5, 6, be moved at at least one oblique angle of incidence, in particular between 5 and 25°, relative to the respective surface of the blank 10 to be machined, regardless of its specific configuration, i.e., in particular regardless of whether it is a roughing or finishing milling cutter or a torus milling cutter. A corresponding oblique orientation (position) of the first machining tool 40 relative to the, as mentioned, (essentially) horizontally oriented top or bottom side of the blank 10 can result in advantages with regard to the material removal by machining.

[0074] In particular, the first machining tool 40 can be moved at several different angles of incidence relative to the surface of the blank 10 to be machined, in particular such that the first machining tool 40 is moved at a first angle of incidence along a first section of the blank 10 to be machined and at a second angle of incidence along a second section of the blank 10 to be machined, which section is oriented obliquely to the first section. A correspondingly variable oblique orientation (angle) of the first machining tool 40 relative to the (essentially) horizontally oriented top and bottom sides 11, 12 of the blank 10, as mentioned, can result in advantages with regard to the material removal by machining. This can apply in particular if the blank 10, as mentioned, is rotated or pivoted about a horizontal axis during machining.Thus, the setting of corresponding angles of attack can be coordinated or synchronized with rotational or pivoting movements of the blank 10 and with movements of the first machining tool 40 along the surface of the blank 10, in particular such that the first machining tool 40 can always be moved over a (substantially) horizontally oriented surface of the blank 10. This can be realized, for example, via the control system mentioned above.

[0075] The method may further include or comprise a step of transferring the intermediate component 20 into a second orientation and a step of machining the intermediate component 20 in the second orientation to form desired surface properties of the intermediate component 20. The machining of the intermediate component 20 in the second orientation typically occurs before the intermediate component 20 is separated from the remaining blank (section), i.e., in particular, a corresponding clamping section. The second orientation may, for example, be an orientation inclined at an angle, in particular at a right angle, with respect to the horizontal orientation given in the first clamping.

[0076] The machining of the intermediate component 20 in the second orientation can be carried out using a second machining tool that is different from the first machining tool 40. A roughing or finishing milling cutter, for example, can be used as the second machining tool.

[0077] The described method can be implemented using a machining device for producing an elongated component having an upper and a lower side 11, 12, in particular a connecting component, furthermore in particular a bone plate. The machining device comprises at least: at least one clamping device for clamping a blank 10 to be machined, in particular having a plate-like or plate-shaped basic shape, at least in a first orientation; at least one first machining tool 40 for machining a blank 10 clamped by means of the clamping device in the first orientation for exposing or peeling out at least the upper and lower sides 11, 12 of the blank.surfaces forming a component to be manufactured by means of the first machining tool 40, forming an intermediate component 20; and a separation device for separating a correspondingly formed intermediate component 20 from the remaining blank (section). Typically, the machining device also comprises a control device implemented in hardware and / or software, which is configured to control the operation of the machining device and the devices associated therewith.

[0078] The clamping device can be configured to rotate or pivot a blank and to transfer an intermediate component 20, in particular by rotating or pivoting about a horizontal or vertical pivot axis, into at least one second orientation. In particular, the clamping device can be configured to transfer an intermediate component 20, in particular by rotating or pivoting about a horizontal rotation or pivot axis, into at least one second orientation while the blank is being machined by means of the first machining tool.

[0079] The machining device may further comprise a second machining tool for machining the intermediate component 20 in the at least one second orientation to form desired surface properties of the intermediate component 20. The second machining tool, although typically also a milling tool, is a machining tool configured differently from the first machining tool 40.

[0080] The first and / or second machining tool of the machining device can be a roughing or finishing milling cutter or a torus milling cutter.

[0081] The first machining tool 40 can be positioned at at least one angle of attack relative to a surface of a blank 10 to be machined by machining, and can be moved relative to the machining surface of the blank 10 when positioned at the angle of attack. In particular, the first machining tool 40 can be positioned at multiple angles of attack relative to the surface of the blank 10 to be machined via a corresponding bearing, so that equal or unequal angles of attack can be realized with corresponding rotational or pivoting movements of the blank 10 during machining.

Claims

PATEN TAN SAYINGS 1. A method for producing an elongated component having a top and a bottom side, in particular a connecting component, comprising the steps: - clamping a blank (10) to be machined, in particular having a plate-like basic shape, in a first clamping, in particular horizontal orientation; - machining the blank (10) in the first orientation to expose at least surfaces representing the top and bottom of the component to be produced by means of a first machining tool (40) to form an intermediate component (20); - Separating the intermediate component (20) from the remaining blank (10).

2. Method according to claim 1, wherein the blank (10) to be machined is rotated or pivoted during the machining, so that the first machining tool (40) can expose an upper side of the component to be produced in at least one first rotational position of the blank (10) and can expose an underside of the component to be produced in at least one second rotational position, in particular rotated by 180° relative to the first rotational position.

3. Method according to claim 1 or 2, comprising a step of transferring the intermediate component (20) into a second orientation and a step of machining the intermediate component (20) in the second orientation to form desired surface properties of the intermediate component (20).

4. The method according to claim 3, wherein the machining of the intermediate component (20) in the second orientation takes place before the separation of the intermediate component from the remaining blank (10).

5. The method according to claim 3 or 4, wherein the machining of the intermediate component (20) in the second orientation is carried out by means of a second machining tool.

6. The method according to claim 5, wherein a roughing or finishing milling cutter is used as the second machining tool.

7. Method according to one of the preceding claims, wherein the machining of the blank (10) in the first orientation comprises a release of at least one surface, which represents a lateral edge region of the component to be produced, by means of the first machining tool (40).

8. Method according to one of the preceding claims, wherein a roughing or finishing milling cutter is used as the first machining tool (40), or wherein a torus milling cutter is used as the first machining tool (40).

9. Method according to one of the preceding claims, wherein the first machining tool (40) is moved at at least one oblique angle of attack, in particular between 5 and 25°, relative to the surface of the blank (10) to be machined.

10. Method according to one of the preceding claims, wherein the first machining tool (40) is moved at a plurality of different angles of attack relative to the surface of the blank (10) to be machined, in particular such that the first machining tool (40) is moved at a first angle of attack along a first section of the blank (10) to be machined and is moved at a second angle of attack along a second section of the blank (10) to be machined, which section is aligned obliquely to the first section.

11. Method according to one of the preceding claims, wherein the intermediate component (20) has an oversize of less than 5 mm, in particular less than 3 mm, in particular less than 1 mm, with respect to the component to be produced.

12. Method according to one of the preceding claims, further comprising a processing step of introducing at least one Fastening interface, in particular a bore, further in particular a threaded bore, in the intermediate component (20) or in the component.

13. Method according to one of the preceding claims, wherein the intermediate component (20) represents the basic shape of the connecting component to be produced.

14. Method according to one of the preceding claims, wherein the component to be produced is a bone plate.

15. Processing device for producing an elongated component having an upper and a lower side, in particular a connecting component, further in particular a bone plate, comprising: - at least one clamping device for clamping a blank (10) to be machined, in particular having a plate-like basic shape, at least in a first orientation, in particular in a horizontal orientation; - at least one machining tool for machining a blank (10) clamped by means of the clamping device in the first orientation for exposing at least surfaces representing the top and bottom of the component or components to be produced by means of the first machining tool, thereby forming an intermediate component (20); - a separating device for separating a correspondingly designed intermediate component (20) from the remaining blank (10); and - a control device for controlling the operation of the processing device.

16. Machining device according to claim 15, wherein the clamping device is configured to rotate or pivot the blank (10) and / or the intermediate component (20), in particular about a horizontal rotation or pivot axis.

17. Machining device according to claim 15 or 16, further comprising a second machining tool for machining the intermediate component (20) in the second orientation to form desired surface properties of the intermediate component (20).

18. Machining device according to one of claims 15 to 17, wherein the first and / or second machining tool (40) is a roughing or finishing milling cutter or a torus milling cutter.

19. Machining device according to one of claims 15 to 18, wherein the first machining tool (40) can be brought into at least one angle of attack relative to a surface to be machined and, in the state brought into the angle of attack, is movable relative to the surface to be machined.

20. Control device, in particular a control device implemented in hardware and / or software, for a processing device according to one of claims 15 to 19, wherein the control device is configured to control the operation of the processing device.

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