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Acetabular cup

Since cobalt chrome is an abrasive material, the challenges when machining the internal sphere include getting a high surface finish, reducing vibration using longer tools and getting inserts to run a full batch.

vc can be altered, but pushing feed (fn /fz) above 0.15 mm (0.006 inch) is very destructive to tool life.

 
acetabula-cup-internal-sphere.jpg
Benefits
  • Highly effective process with circular ramping
  • Longer tool life and less tool breakage
  • Secure process
  • Short cycle time
  • High quality surfaces with positive round inserts
 
hip-circular-interpolation-milling_060330.jpg
 
Machining solution
  1. Drilling with CoroDrill® 846
  2. Circular interpolation milling with CoroMill® 216 
    (for more information, see below)
  3. Semi finish turning with positive round insert 
  4. Finish turning with positive round insert 
    (for more information, see below)
  5. Parting off
  6. Polishing
Machining solution – circular interpolation milling
Circular interpolation generates a constant spiral to generate a rough form for the semi finishing tool. Use a 1.5 mm (0.060 inch) spiral tool path pitch.
 
​​
​​Circular i​nter​polation milling with CoroMill® 216
Tool:
​Holder​R216-20A25-055
​Insert​R216-20 T3 E-M 1025
 ​
​​​Typical cutting data for the operation:
​ap​1.5 mm (0.060 inch) as per spiral
​vc​100–130 m/min (328–427 ft/min)
​fn​0.1 / 0.13 mm/tooth 
(0.004 / 0.005 in/tooth)
Centre line feed
    
Result:
​Cycle time​59 s (depending on cup size)
 ​  
 
Machining solution​ - finish turning
​​
​​Finish turning preparing for polishing
Tool:
​Holder​A20M-SRXDR/L 08-R
​Insert​R300-0828E-PL 530
 ​
​​​Typical cutting data for the operation:
​ap​0.1 mm (0.004 inch)
​vc​40–60 m/min (131–197 ft/min)
​fn​0.03–0.07 mm/r
(0.001–0.003 in/rev)​
    
Result:
​Cycle time​80 s
 ​  
 
Selected component features
 
 
The challenges when machining the external sphere include getting good chip control, reducing vibrations with longer tools and getting inserts to run a full batch.
 
It is important to have a dedicated fixturing in sub spindle.

 
acetabula-cup-external-sphere.jpg
Benefits:
  • Increased tool life
  • Secure process
 
Machining solution
  1. Roughing: Use T-Max P.  Use HP for chip control and process security.
  2. Semi Finish / Finish turning: Use positive round insert 
    (for more information, see below)
Machining solution – semi finish/finish turning
 
​​
​​Semi finish/finish turning the OD sphere
Tool:
​Holder​A20M-SRXDR 08-R
​Insert​R300-0828E-PM S30T
 ​
​​​Typical cutting data for the operation:
​ap​0.1–0.4 mm (0.004–0.016 inch)
​vc​100 m/min (328 ft/min)
​fn​0.05–0.12 mm/r
(0.002–0.005 in/rev)
    
Result:
​Cycle time​28 s
 ​  
 
 
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