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Bone drilling is a crucial operation in orthopedic, maxillofacial, and trauma surgery. Delamination is a familiar defect in the drilling process and can seriously disrupt postoperative regeneration near the implant site in bone surgery. This research experimentally investigates the problem of delamination around drilled holes in vibration-assisted...
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... a well-known surgical operation in orthopedics and has been widely discussed in literature [1][2][3]. Mechanical and thermal damage associated with the process can hamper the engagement of metallic fixative components to the bone adjacent to the drilled hole, eventually causing failure of fixation [4]. A typical fixation in long bone is shown in Fig. 1. Delamination around the drilled hole is a common phenomenon mostly found in drilling of almost all engineering materials and biomaterials. Delamination causes serious damage by dramatically reducing the load-bearing capability of composite structures [5]. Some of the known reasons causing delamination or microfracturing in composites ...
Citations
... Previous research tried to control the temperature and forces through the study of parameters, technique modification, and parametric optimization [8][9][10][11][12][13]. From the aforesaid reports, the heat generation in bone during drilling directly depends on drilling parameters. ...
... Bovine cortical bones were acquired from the local slaughter used for the experiment purpose. Human and bovine bone have similar mechanical and thermal properties [7,10,12,[32][33][34][35][36][37]. To maintain the properties of bovine bone, the acquired bones preserved in saline solution at − 10°C. ...
... International Journal on Interactive Design and Manufacturing (IJIDeM) [26], friction angle (β) 37°, and rake angle (α) 25°. For that purpose, the shear angle F 39°N ext, use equation to determine the typical cutting velocity (12). As the chisel edge diameter was far smaller than the drill bit diameter in this instance, it was disregarded. ...
The development of heat as well as the thrust force that is produced during the cortical bone drilling is emphasised in the present work. Experiments were conducted using two distinct kinds of tools and varying combinations of drilling parameters (rotational speed and feed rate) (conventional drill bit and cylindrical abrasive tool). A thermocouple and a dynamometer were used to record the increase in temperature as well as the force that was applied. A mathematical model was built in order to predict the amount of heat that was transferred from the drill bit to the bone as well as the amount of tension that was induced throughout the drilling process. Because the findings of the mathematical model were validated against the experimental data, using a mathematical model to forecast the heat generation and force induced to the cortical bone during drilling is an effective method. The primary zone heat found to be 0.217 w and thrust force found to be 1.42 N with the developed mathematical model. The model that was proposed can be used to make predictions about the values of the drilling parameters that could be used for optimal cortical bone drilling without inflicting any damage to the fundamental structure of the bone.
... Moreover, fewer and shorter microcracks were observed for RUBD as compared to holes drilled with CSBD. Alam and Qamar [10] studied the effect of spindle speed and feed rate on delamination in bovine bone drilling using conventional drilling (CD) and ultrasonic-assisted drilling (UAD). It is showed that drilling speed no significant effect on the level of delamination in both CD and UAD. ...
Direct approach for bone fracture treatment usually involves restoring the fractured parts to their initial position and immobilizing them with plates, screws and wires. This approach needs a bone surgery drilling to produce hole for screw insertion. But this drilling process causes mechanical damages, i.e microcracks, burr formation and delamination, that can reduce the stability of the fixation. One of the ways to minimize it is by using coolant. Moreover, it is noted that bone has anisotropic microstucture. The object of this study is to understand the effect of coolant on mechanical damages that occur in bone drilling and to understand the effect of microstructure difference on microcracks that occur in the drilled walls holes. Adult bovine bones and adult goat bones were used in this study as the specimens to represent differences in cortical bone microstructure. Five consecutive holes from the distal to the proximal in each specimen were generated using manual hand-drill (spindle speed (n) = 1000 rpm; drill bit (d) = 4 mm diameter) with the use of coolant as variation. The drilling holes then stained and observed using a microscope. As the result, it was found that the use of coolant can significantly reduce the drilling temperature. Microcracks, burr formation and delamination were found to be quite large in the drilling holes without coolant. However, there is no microcrack found in the drilling holes with coolant, there is only a small number of burr formation was found. In addition, it was found that the differences in bone microstructure affect the number and length of microcracks that occur in the wall of the hole. It can be concluded from this study that the application of coolant is very effective to reduce the drilling temperature and enhancing the quality of the hole generated by bone drilling and the higher the density of osteon in cortical bone, the easier the microcrack to initiate and propagate.
... In this study, a fresh bovine femur was selected for this study because its mechanical properties are similar to human bone [34]. The two ends of the bone (Epiphysis) were cut, and its rod-shaped portion (Diaphysis) that has cortical structure was the subject of the experiments. ...
Low cutting forces can signi cantly reduce the risk of damage to sensitive tissues adjacent to the bone. Because of its better control of the incision, lower cutting force and reduced postoperative complications, the application of ultrasonic tools in bone-cutting is of concern to surgeons. In this study, through the application of a full factorial design of experiments, the e ects of changes in cutting tool geometry, ultrasonic power, bone-cutting direction, and tool speed on the cutting forces of cortical bone are assessed simultaneously. The variance and regression of the experimental data are analyzed, and the impact of factors and interactions of the elements on the cutting forces are discussed. The adjusted coe cient of determination (R 2 adj) of the main cutting force and cutting resistance force of the statistical model were 91.49% and 91.15%, respectively. Both the blade geometry and ultrasonic power, together with their interactions, are the most in uential factors in the cutting forces, contributing 82.2% and 86.6%, respectively. The formation of teeth in the cutting edge improves the cutting process and reduces the cutting force by about 40%. To obtain high e ciency and low cutting force, it is recommended to use an ultrasonic-powered toothed edge blade with a pitch of 1 mm, a low vertical velocity, and a high longitudinal speed.
Owing to its outstanding and superior properties, alumina is a well-documented advanced ceramic to realize numerous manufacturing and medical applications. However, machining alumina using traditional techniques is difficult, time-consuming, and sometimes impossible due to its high hardness, brittleness, and low electrical and thermal conductivity. Rotary Ultrasonic Machining (RUM) is among the most frequently reported methods for drilling holes in ceramics. However, extensive edge chipping is also noticeable in RUM both at the entrance and at the exit of the hole if correct machining variables are not considered. This research, therefore, focuses on experimentally exploring the significance of RUM control variables, notably: spindle speed, feed rate, ultrasonic amplitude, and ultrasonic frequency on edge chipping and surface roughness. The experiments are planned through the response surface methodology, which is dependent on a central composite rotatable design. The distinctive selection of RUM parameters that mitigate edge chipping may produce unfavorable outcomes for the surface finish. This assumption underlines the necessity of multi-objective optimization to ensure competitive RUM efficacy for hole drilling in alumina. A gray relational analysis paired with a principal component analysis (GRA–PCA) framework is embraced to identify optimal drilling variables for RUM. The procedure of optimizing multiple quality attributes (edge chipping and surface roughness) to elevate the quality of hole drilling in alumina ceramic using the GRA–PCA method is illustrated. According to this study, the feed, along with speed, amplitude, and frequency, has the biggest impact on RUM efficacy. The findings of this investigation reveal that the minimal surface roughness (Ra = 0.29 µm and Rt = 1.19 µm) and lowest area of edge chipping at the hole entrance and exit (0.29 mm2 and 1.36 mm2, respectively) can be achieved using the following parameters: speed −6000 rpm, feed rate −0.5 mm/min, amplitude −35 µm, and frequency −23 kHz.
Bone drilling is a universal procedure in orthopaedics for fracture fixation, installing implants, or reconstructive surgery. Surgical drills are subjected to wear caused by their repeated use, thermal fatigue, irrigation with saline solution, and sterilization process. Wear of the cutting edges of a drill bit (worn drill) is detrimental for bone tissues and can seriously affect its performance. The aim of this study is to move closer to minimally invasive surgical procedures in bones by investigating the effect of wear of surgical drill bits on their performance. The surface quality of the drill was found to influence the bone temperature, the axial force, the torque and the extent of biological damage around the drilling region. Worn drill produced heat above the threshold level related to thermal necrosis at a depth equal to the wall thickness of an adult human bone. Statistical analysis showed that a sharp drill bit, in combination with a medium drilling speed and drilling at shallow depth, was favourable for safe drilling in bone. This study also suggests the further research on establishing a relationship between surface integrity of a surgical drill bit and irreversible damage that it can induce in delicate tissues of bone using different drill sizes as well as drilling parameters and conditions.
In orthopedics and surgery, bone drilling is an important operation for inserting screws and fixing prostheses. A nonnegligible problem which can affect post-operative recovery is the thermal necrosis. For this problem, the method of low-frequency vibration-assisted drilling (LFVAD) was applied in the process of bone drilling in this paper. The influences of parameters (feed rate, rotational speed, vibration frequency and amplitude) on the cutting performances (cutting temperature and chip morphology) were investigated. The results indicate that LFVAD can produce lower temperature compared with conventional drilling (CD). In LFVAD, rotational speed and vibration amplitude are more important parameters on the drilling temperature and chip morphology compared to feed rate and vibration frequency. In addition, according to the trajectories of the cutting edge of drill bit, a mathematical model of heat generation and dissipation was developed in LFVAD.
High precision and close tolerance is an essential requirement of current manufacturing industries dealing in micro-fabrication. The quality of surface obtained after machining process exhibits the utility of product. The various material and alloys are developed continuously to fulfill the need of application in critical conditions. The versatile characteristics of material also required a modification in manufacturing processes. The exotic material required a special treatment of machining to avoid the failure. Various methods of conventional, un-conventional and their hybrids have been developed to meet the above requirement. Wherein, ultrasonic vibration assistance has been extensively applied in numerous manufacturing processes to increase the process performance. In present review, ultrasonic vibration (UV)-assisted manufacturing processes for machining/finishing are covered using selected materials. Additionally, the benefits of UV assistance in welding such as arc compression, plasma pressure are discussed in details. Moreover, assistance of vibration in non-traditional machining processes such as ECM, EDM and AWJM is discussed in detail with their effects. In machining, ultrasonic assistance facilitate basic process by reduction in cutting force, and improvement in the machined morphology. Thus, the outcomes obtained from the large number of published literatures strongly demonstrate the significance of ultrasonic vibration in various sections of present article.
This article reviews environmentally friendly and/or cost-effective processes. Topics covered are minimum-quantity-lubrication (MQL), cryogenic-cooling and near-dry-machining; polishing slurries; recycled metals; processing wood materials; microfluidic paper devices; life-cycle-assessment; electrical-discharge-machining; friction-stir-processing; and green and/or cost-effective processes. Findings include that environmentally-friendly-slurries are hot research-topics for polishing wafers. For cost, health and environment considerations, MQL emerges as a popular and innovative-research topic. To augment material yield and decrease pollution, solid-state-recycling was conducted to recycle chips. Waterjet turning of wood composites solved the problems of the matrix sticking to machining tools. The performance of wood products is significantly influenced by their surface roughness, which depends on machining processes and anatomical wood structures. Novel approaches were proposed for fast-manufacturing of microfluidic paper devices, with advantages of low energy-consumption and costs. Lifecycle models resulted in indicators under resources, ecosystem quality and human health, and provided the information for further advances of environmentally-friendly processes. Electric discharge machining (EDM) employs hydrocarbons-based dielectrics, and this generates hazardous gas-emission and leads to safety, health and environmental issues. To overcome the problems, innovative green-machining was proposed by conducting sustainable near-dry EDM, which significantly decreased gas-emissions. Copper foam plates were sintered by employing friction stir welding, and the method was cost-effective.
This study investigates neurosurgical bone grinding with varying parameters on skull bone using a miniature grinding burr. Three process parameters, namely, rotational speed, feed rate, and depth of cut, have been investigated at three different levels in the terms of tangential force, thrust force, and torque generated during grinding. The results revealed that as the rotational speed is increased, the cutting forces and torque showed a decreasing trend. Nevertheless, the increase in feed rate and depth of cut leads to the escalation in response characteristics. The best parametric combination for minimum cutting forces and torque is as follows: rotational speed = 55,000 r/min, feed rate = 20 mm/min, and depth of cut = 0.50 mm. Morphological analysis reveals cracks in the bone’s surface at a higher feed rate. Furthermore, delamination and cutting streaks are also visible on the surface of the bone after grinding. Energy-dispersive spectroscopy and elemental mapping of the tool after bone grinding indicate the accumulation of the bone chips in the successive diamond abrasives. The outcomes of the study will be beneficial for the neurosurgeons in understanding the effect of various process parameters on cutting force, toque, microcracks, and bone’s regeneration ability during surgical bone grinding.
