Machining knee joint

An artificial knee joint - a partial or total endoprosthesis that functions as a replacement knee joint. The joint consists of a liner, a femoral component and a tibia component.

Forms the connection to the lower leg (tibia) and simultaneously serves as the seating surface for the gliding component

Replaces the cartilage lining, thereby improving the gliding properties within the joint

This component – which constitutes a shaped surface – mimics the movement of the knee and glides on the liner

1. Machining: tibia component

1. S-Cut solid carbide milling cutter

Milling the outside profile using the S-Cut: produces contours with the maximum depth of cut and a high material removal rate

  • Low power consumption
  • Longer tool life thanks to the S-shaped cutting edge
  • Innovative geometry for increased feed
  • Extremely irregular pitch
  • Cutting edge follows an S-shape

The S-Cut performs brilliantly with Co-Cr, even if the Ae value is low. A long service life can be achieved as a result of the innovative cutting edge geometry. 

2. Special T-slot milling cutter with angled geometry

Milling the clip-in area

  • Adapted to the relevant situation
  • High surface quality on side walls
  • Available in spiralised version

When it comes to the required angle tolerance and surface quality, the clip-in area can sometimes be very sensitive. The solid carbide T-slot milling cutters are tailored accordingly in each case. During this process, the cutting situation, dimensions and requirements are all factored into the design. 

3. Special solid carbide milling cutter for high removal rates

Milling the inside contour of the base 

  • Optimised for internal radii
  • Can be supplied with wiper geometry if required
  • Low power consumption
  • Innovative cutting edge shape
  • Extremely irregular pitch and irregular helix
  • Large chip spaces

4. Face milling with MultiLock & MaxiMill

Base surface of the tibia component created with the innovative MultiLock system 

  • Excellent price-performance ratio
  • Directly pressed, precision sintered interface
  • Low proportion of carbide
  • Extremely stable head retainer
  • Max. axial and radial run-out accuracy of 20µm
  • Various head designs available

The MultiLock offers excellent performance in combination with extreme stability and maximum flexibility. 

MaxiMill 271 – Face milling with extreme cutting depths

  • Sturdy base body design for high loads
  • 8 usable cutting edges per indexable insert
  • Double-sided negative indexable insert with integrated clearance angle for reduced cutting forces and smooth cutting
  • Results in high surface quality
  • Available as a face milling cutter or high-feed milling cutter

5. Turning with X7 line

Basis turning - roughing with -M34 in CTPX710 

  • Medium chip breaker for machining HRSA
  • X7 grade ensures optimum results
  • CTPX710 Dragonskin coating
  • Extremely long tool life

Thanks to their innovative PVD coating, the X7 grades are ideal for universal application. When used with super alloys, their performance is particularly impressive. 

Basis turning - finishing: X7 line for optimum results with HRSA

  • Positive, ground turning inserts
  • F05 chip breaker for fine finishing
  • Ultra-precise indexable inserts with F05 chip breaker
  • Significantly tighter tolerance class
  • Available with "G" and "E" tolerances

The F05 chip breaker can be used to achieve superb chip control even with small depths of cut. In addition, the F05 offers significantly improved indexing accuracy. 

6. Special threaded core hole drill

Pre-drilling of thread core hole with countersink

  • Individually customisable stepped drill
  • Drilling and chamfering for subsequent thread
  • Available with multiple cutting edges
  • Optimised for use on HRSA
  • Multi-stage and tapered options

Thread milling cutter with standard (DIN) and special dimensions

  • Special surface finish results in quieter running
  • Any type of thread can be produced
  • Extremely long tool life
  • Significantly higher number of cutting edges

MGF HPC thread milling cutters are the fastest tools available on the market. They are also highly precise, making them ideal for zero-defect thread requirements. 

2. Machining: Liner

1. Material removal with MaxiMill HSC-11

Maximum machining power for removing large volumes of material

  • Extremely sharp cutting edge
  • High rake angle
  • Ideal for use on plastics
  • High removal rates
  • Wide choice of corner radii: from 0.2 mm to 5.0 mm
  • Available in the following variants: end mill, face mill and screw-in cutter

The HSC-11 milling cutter range is ideal for removing material from plastics such as UHMWPE. 

2. PCD/CVD/MCD-tipped milling cutters

Mirror finish milling of the contours (gliding surfaces) on the top side of the liner

  • Mirror finish milling of surfaces without score marks
  • Long service life
  • Available with or without chip breaker
  • Standard range available

3. Pre-contouring with AluLine roughing tool

Ballnose and full radius milling cutters produce the free-form surfaces on the top side of the liner

  • Extremely sharp cutting edge
  • Modification of the cutting edge for improved chip control
  • High rate of material removal
  • Low heat generation
  • Polished chip flutes reduce sticking tendency
  • Reduced cutting force

4. Single-tooth end mill

Material removal and outer shape

  • Extremely low burr formation
  • Very sharp geometry and cutting edge design
  • Large polished chip space
  • Submersible

3. Machining: Femoral component

1. Pre-milling the outside profile with SilverLine

Removal of casting residues from the gliding surfaces (condyles and patella shield)

  • Reinforced core diameter -> greater stability
  • Large product range
  • Optimised core geometry -> low levels of vibration
  • Tool life increased by > 10%

The new SilverLine has been thoroughly revised for use on HRSA with demanding parameters. The new cutting edge geometry reduces the cutting forces and vibrations, thereby improving surface quality. 

2. Milling gliding surfaces with special solid carbide barrel milling cutter

Customised barrel milling cutters or ballnose milling cutters for creating the gliding surfaces of the joint

  • Excellent surface quality can be achieved
  • Short machining times
  • Large line skip
  • Long service life

In conjunction with suitable CAM programs, the barrel milling cutters are the key to high levels of effectiveness. 

3. Milling of the box

Tapered solid carbide milling cutter with corner radius 

  • Geometry optimised for machining HRSA
  • Increasing core diameter
  • Angles and radii are matched to the component

The use of CAM systems ensures improved accessibility and the ideal cut distribution. Cutting edges are designed for use on walls with a set orientation. 

4. Traditional machining with MultiLock

MultiLock with ball nose insert as a cost-effective means of milling the gliding surfaces line by line

  • Excellent price-performance ratio
  • Directly pressed, precision sintered interface
  • Low proportion of carbide
  • Extremely stable head retainer
  • Max. axial and radial run-out accuracy of 20µm
  • Various head designs available

The MultiLock offers excellent performance in combination with extreme stability and maximum flexibility. 

5. Internal retaining thread with MGF HPC thread milling cutter

Thread milling cutter with standard (DIN) and special dimensions

  • Special surface finish results in quieter running
  • Any type of thread can be produced
  • Extremely long tool life
  • Significantly higher number of cutting edges
  • From M1 

MGF HPC thread milling cutters are the fastest tools available on the market. They are also highly precise, making them ideal for zero-defect thread requirements.