Non-Circular-Rotary-Turning process for manufacturing parts with non-circular contours

Modern medical implants are characterized by non-circular shapes, which is often challenging for economic production. Non-Circular-Rotary-Turning (NCRT) is a newly developed process for manufacturing non-circular cross-sections at high productivity and a high degree of geometric freedom. In this work, the basic process kinematics of NCRT are presented. A process design method is proposed and validated. The fundamental cutting conditions are examined using simulation and the cutting forces are studied experimentally. In an example of application, NCRT enables to reduce machining time by a factor of more than ten compared to a conventional process chain, resulting even in better surface quality.