Pre-Fluted Dental Tool Machining for Accurate Cutting End Orientation
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Solution Overview
Problem
Current manufacturing methods for dental milling tools are inefficient, particularly in forming the desired shape and profile, as they involve time-consuming grinding operations and inaccuracies in shaping the tool's cutting end region.
Innovation Solution
The method involves using a pre-fluted blank with an orientation indicator, where a probe identifies the flute orientation, allowing precise alignment and formation of the cutting end region in a separate machine, enabling efficient machining and reducing overall manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional grinding operations are used to form the cutting end region and flutes on a uniform blank, then the tool shape can be formed, but the manufacturing time is excessive and productivity is low
Solution Approach 1:
The flutes are pre-formed on a blank before the cutting end region is created. This preliminary action allows the flutes to be formed in advance using optimized processes, and then the blank with pre-formed flutes is positioned and oriented using a probe to identify flute orientation, enabling efficient formation of the cutting end region without re-grinding flutes, thus significantly reducing total manufacturing time while maintaining precision
Solution Approach 2:
The manufacturing process is segmented into distinct operations: (1) forming flutes on a blank, (2) positioning the pre-fluted blank in a machine, (3) using a probe to identify flute orientation, and (4) forming the cutting end region. This segmentation allows each operation to be optimized independently and enables potential outsourcing of flute formation to specialized manufacturers, improving overall productivity
2Manufacturing precision
If multiple grinding operations are performed in sequence to form the tool shape, then the desired profile can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The flutes are formed as a preliminary action before the main cutting end region formation. This eliminates the need for complex sequential grinding operations to create both flutes and cutting end, as the flutes are already in place. The process complexity is reduced to mainly positioning and orientation steps using the probe system
Solution Approach 2:
The probe acts as an intermediary between the pre-fluted blank and the cutting end region formation process. It identifies the flute orientation and provides this information to control the machine, enabling accurate positioning without complex measurement and calculation procedures, thus simplifying the overall process
3Ease of manufacture
If the blank is positioned and oriented manually or without probe identification, then setup is simpler, but alignment accuracy between the cutting end region and flutes deteriorates
Solution Approach 1:
The pre-fluted blank essentially identifies its own orientation through the probe detecting the flute geometry. The flute structure itself serves as the reference feature, eliminating the need for external fixtures or complex alignment procedures. The probe automatically detects flute orientation and the machine control system uses this information to position the cutting end region accurately, achieving both simplicity and precision
Data Source
AI summary
A method for manufacturing a dental or medical tool the method comprising the steps of positioning a pre-fluted blank 14 including a stem 24 and a shank 22 within a machine 30, using a probe to identify a position and/or an orientation of at least one flute 26 of the pre-fluted blank 14 and/or the position and/or orientation of an orientation indicator 28 of the pre-fluted blank 14, and using the machine 30 to form a cutting end region 36 at the end of the stem 24 of the pre-fluted blank 14 remote from the shank 22, the flute 26 extending into the cutting end region 36, the machine 30 being controlled to ensure that the cutting end region 36 is correctly orientated relative to the flutes 26 of the pre-fluted blank 14.