Process planning and contour-based error compensation for precision grinding of miniature scalpels

IF 4.2 2区工程技术 Q2 ENGINEERING, MANUFACTURING Advances in Manufacturing Pub Date : 2023-08-23 DOI:10.1007/s40436-023-00458-w

Cheng Fan, Cao-Yang Xue, Jun Zhao, Wei Jiang, Wen-Ge Han, Lei Zhang, Li-Ning Sun

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Abstract

Miniature scalpels are mainly used in microsurgeries such as ophthalmic and cardiovascular surgeries. The size of a miniature scalpel is only a few millimeters, and the precision of the blade shape is high, which makes production of miniature scalpels extremely difficult. This study proposes a new sharpening process for grinding miniature scalpels on a four-axis machine tool. A post-processing algorithm for a four-axis grinding machine based on a kinematics model is established. We then propose a corresponding parameter calibration method for the parameters used in the kinematics model. Because of possible errors in the parameter calibration, a contour-based error compensation method is proposed for accurate adjustments to the edge shape following grinding. This can solve the problem of large deviations between the actual edge shape after grinding and the ideal edge shape. The effectiveness of the proposed process planning and error compensation method is verified experimentally, and the grinding process parameters of the miniature scalpel are optimized to improve its surface processing quality. The sharpness of the optimized miniature scalpel is less than 0.75 N, and the blade shape is symmetrical, which meets the technical requirements of miniature scalpels.

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微型手术刀精密磨削工艺规划及基于轮廓的误差补偿

微型手术刀主要用于眼科和心血管外科等显微手术。微型手术刀的尺寸只有几毫米，对刀刃形状的精度要求很高，这给微型手术刀的生产带来了极大的困难。本研究提出了一种在四轴机床上磨削微型手术刀的新刃磨工艺。建立了基于运动学模型的四轴磨床后处理算法。然后，我们为运动学模型中使用的参数提出了相应的参数校准方法。由于参数校准可能存在误差，我们提出了一种基于轮廓的误差补偿方法，用于在磨削后对边缘形状进行精确调整。这可以解决磨削后实际边缘形状与理想边缘形状之间存在较大偏差的问题。实验验证了所提出的工艺规划和误差补偿方法的有效性，并优化了微型手术刀的磨削工艺参数，提高了其表面加工质量。优化后的微型手术刀锋利度小于 0.75 N，刀刃形状对称，满足了微型手术刀的技术要求。

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来源期刊

Advances in Manufacturing Materials Science-Polymers and Plastics

CiteScore

9.10

自引率

3.80%

发文量

274

期刊介绍： As an innovative, fundamental and scientific journal, Advances in Manufacturing aims to describe the latest regional and global research results and forefront developments in advanced manufacturing field. As such, it serves as an international platform for academic exchange between experts, scholars and researchers in this field. All articles in Advances in Manufacturing are peer reviewed. Respected scholars from the fields of advanced manufacturing fields will be invited to write some comments. We also encourage and give priority to research papers that have made major breakthroughs or innovations in the fundamental theory. The targeted fields include: manufacturing automation, mechatronics and robotics, precision manufacturing and control, micro-nano-manufacturing, green manufacturing, design in manufacturing, metallic and nonmetallic materials in manufacturing, metallurgical process, etc. The forms of articles include (but not limited to): academic articles, research reports, and general reviews.