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

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

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

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (1) : 108 -123.

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Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (1) : 108 -123. DOI: 10.1007/s40436-023-00458-w

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

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¹ Jiangsu Provincial Key Laboratory of Advanced Robotics, School of Mechanical and Electrical Engineering, Soochow University, 215021, Suzhou, Jiangsu, People’s Republic of China

² Key Laboratory of Fluid Power and Mechatronic Systems, School of Mechanical and Electrical Engineering, Zhejiang University, 310027, Hangzhou, People’s Republic of China

³ State Key Laboratory of Intelligent Equipment and Manufacturing, School of Mechanical Engineering, Zhejiang University of Technology, 310023, Hangzhou, People’s Republic of China

^f sudazhanglei@suda.edu.cn

Cheng Fan is an associate professor at the School of Mechanical and Electrical Engineering, Soochow University. He received his Ph.D. from the School of Mechanical Science and Engineering of Jilin University. His research interests include precision manufacturing and adaptively controlled polishing. He has published more than 50 papers and obtained more than 10 national invention patents.

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Cao-Yang Xue is a doctoral student at the School of Mechanical and Electrical Engineering, Zhejiang University. His research interests include grinding of miniature scalpels and error compensation.

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Jun Zhao is an associate professor at the School of Mechanical Engineering, Zhejiang University of Technology. He received his Ph.D. from the School of Mechanical Science and Engineering of Jilin University. His research interests include intelligent and precision manufacturing.

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Wei Jiang is currently studying at the School of Mechanical and Electrical Engineering, Soochow University, and is majoring in precision grinding and equipment development.

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Wen-Ge Han is postgraduate student at the School of Mechanical Engineering of Soochow University and is mainly engaged in intelligent precision manufacturing.

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Lei Zhang is a Professor at the School of Mechanical and Electrical Engineering, Soochow University, Soochow, Jiangsu Province, China. He received his Ph.D. in Mechanical Engineering from Jilin University of Technology, China, in 1999. His research interests include grinding and polishing of freeform surfaces.

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Li-Ning Sun is primarily engaged in research on the structure and control of nanoscale microdrive and micromanipulation robots as well as industrial, medical, and educational robots. He is the winner of the National Fund for Distinguished Young Scholars and a distinguished professor of Changjiang Scholars at the Ministry of Education. He is an expert in the overall group of the key science and technology special project for service robots at the Ministry of Science and Technology of the People's Republic of China. He has published more than 200 papers and obtained more than 20 national invention patents.

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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.

Keywords

Miniature scalpel / Sharpening / Kinematics / Error compensation / Grinding

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Cheng Fan, Cao-Yang Xue, Jun Zhao, Wei Jiang, Wen-Ge Han, Lei Zhang, Li-Ning Sun. Process planning and contour-based error compensation for precision grinding of miniature scalpels. Advances in Manufacturing, 2024, 12(1): 108-123 DOI:10.1007/s40436-023-00458-w

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Funding

Key Technologies Research and Development Program http://dx.doi.org/10.13039/501100012165(2021YFB3400300)

National Natural Science Foundation of China http://dx.doi.org/10.13039/501100001809(51975392)

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