More Than A Machine Tool

Paired with the TNL18 is the Traub Winflex programming and simulation software.
Oscor Inc., Palm Harbor, FL, already a successful medical device manufacturer, knows the pace of this industry very well, having taken strong steps to stay ahead of the curve.

The company designs, develops, manufactures, and markets a variety of highly specialized permanent and temporary pacing lead systems. The company's pacing leads used in connection with pacemakers – both implantable and temporary pacemakers systems – treat cardiac bradyarrhythmias (an adult heart rate below 60 beats per minute) and other coronary disorders.

Oscor's proprietary lead technologies have also led to the development of new lead systems for a variety of cardiac and non-cardiac (nerve) applications. These include catheters and introducers for introducing a drug or other substance into the body.

Through a clear focus on product quality and innovation, they have established a strong market position in the United States and internationally. In addition, Oscor sells products in more than 65 countries outside the United States, relied upon by medial OEM to deliver perfection every time.

Oscor handles the entire process, from component design to mold building, component manufacturing, and sterile packaging and labeling, in-house. On its higher volume parts, the company produces in the range of 100,000 parts per month. Typical tolerances are 0.0002" and most parts are less than 0.25" diameter, many are almost too small to see.

  The TNL 18 comes with a tool setting station, w hich requires the turn of only two screws, away from the machine, rather than in the machine itself.To produce the leads, Oscor operates a state-of-the-art machine shop, and recently opened its new tool shop and engineering facility, which adds 50,000ft² of precision tooling and molding, Swiss machining, and other manufacturing capacity. One of the newest machines in the shop is a Traub TNL18 sliding/fixed headstock production-turning machine.

Thomas Osypka, president and CEO, justified the purchase of the Traub partly as a new business tool, something that is allowing the company to design lead parts that have never before been created. For example, a new design for a lead contact concept can provide a range of advantages over a conventional contact.

Osypka points out that the company has been doing Swiss machining for more than 10 years, and that the parts it makes are becoming more complex and smaller than ever. "We found that our current machines were not going to be able to handle these new type parts in a single operation. We looked around for a machine that could do our parts in a short cycle time, and in one operation. The Traub TNL18 was the only machine that could meet our requirements," he says.

Delivered in June 2010, the 7-axis TNL18 came with training and very attentive support from Index Corp. In its first setup at Oscor, the Traub defeated an R&D setup for a high-nickel, chrome and molybdenum part by 3:1 – in a less than 500-piece run. "We see the possibility for even better results as the capabilities of the machine are fully utilized by a well-trained operator," says Udo Wollmann, Oscor director of operations.

As the company loads part programs for current production into the Traub, it is also finding that the convertible machine is able to reduce cycle times on those parts by up to 40%, comparing part for part to its current equipment.

"For us, the number one reason was machine capability. This magnitude of cycle time improvement proves that the Traub machine will be a very worthwhile investment for us," Osypka says.

To date, Oscor is finding that the TNL18 allows the company to optimize every facet of production, minimizing tool wear while reducing cycle time. This is due in part to the training from Index, allowing Traub to help Oscor identify ways to make its parts more efficiently, Wollmann states. As Oscor works with the machine, it is also able to improve its yield of usable parts.

The TNL18 gives Oscor the ability not only to run its current parts faster than before, but also allows the company to pursue the production of parts they have been unable to produce on current machines. This is due to a greater number of axes and more tooling options they have on the TNL.

"We need the extreme flexibility in order to be a leader in our industry and to quote parts we may not have had a chance to earlier. This also opens opportunities for us to discuss new possibilities with potential customers," Wollmann says.

Compared to other Swiss turning machines that the company runs, the TNL18 has the capability to be used as a milling center, because of the range of tooling and axes it features.

According to Wollmann, "Milling data is the same on the Traub as on the company's milling centers, plus you have the option of orienting the part to the tool in many different ways, facilitating chip clearance, and reducing cycle time."

The Traub also enables the company to run a part from bar stock rather than milling blanks, saving a great deal of processing time on those parts. Oscor can also decide not to use the barfeeder when producing shorter runs and extreme tolerances – to 0.02µ.

  The Traub TNL 18 delivers optimized machining for Oscor operators."With the TNL18, you need to be a little bit broader minded than you might be with a typical Swiss machine, this is because of the wider range of capabilities it brings to the parts," Wollmann continues. "This machine does operations I never thought of putting together – that is what I like about it. I have a good imagination, and I do not see the end of what we can do.

"By the same token, it has to become part of your process planning to fully utilize the capabilities and improvements the Traub offers. You cannot process the same old way if you want better results."

Paired with the TNL18 is the Traub Winflex programming and simulation software, which allows the programmer/operator to simulate toolpaths and optimize the programs prior to running parts.

Index provided extensive training for the operator on the machine and the WinFlex simulation programming. With its 2D- or 3D-simulation, which can run backwards and forwards parallel to the program creation, WinFlexIPS is an easy-to-learn program creation option.

WinFlex permits the parallel programming and depiction of up to four sub-systems with simultaneous simulation of the machining, as well as numerous functions for creating, checking, and optimizing the machine process, including a wide range of functions and cycles and clear presentation of all parts systems. Through user-oriented operating controls, part data is input through WinCAD.

"WinFlex is very easy to use. Its tools allow us to do in minutes what would typically take us hours with paper and a calculator, even with my years of experience. We prefer off-line programming so as not to interfere with our production. Three-dimensional simulation also allows us to avoid interference in the machining process," an Oscor machine operator explains. "We have done a few parts already where I have been able to cut the cycle time in half compared to what we run on the other machines due to the versatility of the Traub. I can do overlaps and crosses that typical machines cannot."

Oscor has been loading part programs into the Traub, trying them out first in WinFlex. The operator is finding setup of parts and machining cycle times to be faster, which will become an even greater advantage as parts see greater production volumes

"We are investing into what our future is going to become," says Kevin Wade, tool shop supervisor.

"The only limitation to what you can accomplish on the Traub is in your mind," a machine operator says, "because there is so much there: three tools in the cut at a time, and sub-spindle work simultaneous with 4-spindle work (both spindles at the same time) means there is a lot going on in the machine at all times."

The TNL 18 is capable of multiple machining functions, including milling. The rigidity of the machine's construction is well suited to machining micro-parts in the tough material Oscor uses, including titanium and special steel alloys. The TNL tool positioning is nearly unlimited, allowing Oscor programmers to put the tool points where required very rapidly.
 

Convertibility/Tool Setting
Oscor likes the convertability of the TNL from sliding to fixed headstock.Oscor also likes the convertibility of the TNL from sliding to fixed headstock, which saves production time and dramatically increases the versatility of the machine for the company and the many different parts it produces.

The TNL18 can be changed over in minutes to produce precision parts with or without a guide bush for long or short parts from bar up to 20mm diameter. The extremely long Z-travel distance of the headstock ensures the proper positioning of the main spindle, either for turning with a guide bush or without.

A swiveling sub-spindle is fitted to an X, Y, Z cross-slide, which at the same time carries the bottom tool turret. This slide, with large axis travel distances, provides plenty of space for three-axis reverse side machining, even for geometrically complex workpieces.

The tool capacity of the TNL18 can be increased to as many as 54 tool places through dual- and multi-holders of live and fixed tools, enabling extending productive time. The high-precision turret indexing permits a chip-to-chip time of only 0.3 seconds while the solid back working attachment accommodates seven toolholders, of which three can be driven.

A new concept in tool carriers uses an NC rotary axis without mechanical interlock to permit complete freedom of tool positioning. The tool can be positioned where needed for any machining operation, offering unparalleled processing flexibility.

The machine also came with a tool setting station. "Using the fixture, I can emulate what is in the machine, adjusting the tool with only two screws rather than in the machine," says the operator, "to set the offset. The relationship to the machine is one to one." The different sides of the setting fixture equal each different toolholding situation on the machine.

All toolholders are seated deeply in the turret, resulting in less leverage effect and, in turn, high stiffness. A quick-change system enables high-precision, smooth exchange of tools without removing the toolholder, allowing the compact shaft system to greatly increase tool life, contributing to improved surface quality.

The working area of the TNL18 is easily accessed by the user through a high and wide sliding door. This provides a lot of room for operators to access, easily, the tools and spindles. A large inspection window allows the operator to keep a close eye on the machining process.

According to Osypka, "We will continue to invest in our employees, systems, and technology to support our mission of providing physicians the tools necessary to improve patient outcomes, while reducing recovery times and treatment costs. We believe the TRAUB machine is a very important tool in accomplishing our mission today and into the future with components that have not yet been invented."

INDEX Corp. Noblesville, IN index-usa.com

Oscor Inc. Palm Harbor, FL oscor.com