Experimental investigations and statistical modeling of cutting force and torque in rotary ultrasonic bone drilling of human cadaver bone

2019 ◽  
Vol 234 (2) ◽  
pp. 148-162 ◽  
Author(s):  
Ravinder Pal Singh ◽  
Pulak Mohan Pandey ◽  
Asit Ranjan Mridha ◽  
Tanuj Joshi
Keyword(s):  
Particle Size ◽  
Cutting Force ◽  
Feed Rate ◽  
Abrasive Particle ◽  
Drilling Process ◽  
Human Cadaver ◽  
Drilling Speed ◽  
Bone Drilling ◽  
Drilling Parameters ◽  
Drill Diameter

Cutting force and torque are important factors in the success of the bone drilling process. In the recent past, many attempts have been made to reduce the cutting force and torque in the bone drilling process. In this work, drilling on human cadaver bones has been performed using rotary ultrasonic bone drilling process to investigate the effect of drilling parameters on cutting force and torque. The experimental work was carried on a recently developed rotary ultrasonic bone drilling machine for surgical operations. The experimental work was performed in two phases. The first phase includes a comparative study between rotary ultrasonic bone drilling and conventional surgical bone drilling, to study the influence of various drilling parameters (rotational speed, drill diameter, and drilling tool feed rate) on the cutting force and torque. The results revealed that the cutting force and torque produced during drilling operations in rotary ultrasonic bone drilling were lesser (30%–40%) than conventional surgical bone drilling. In the second phase, response surface methodology was used to perform the statistical modeling of cutting force and torque in rotary ultrasonic bone drilling process. Analysis of variance was performed at a confidence interval of 95% to analyze the significant contribution ( p < 0.05) of process parameters (drilling speed, feed rate, drill diameter, and abrasive particle size) on the responses (cutting force and torque). The confirmatory experiments were performed to validate the developed statistical models. It was found that both cutting force and torque decrease with increase in drilling speed and increases with the increasing drill diameter, feed rate, and abrasive particle size.

In vitro comparison of conventional surgical and rotary ultrasonic bone drilling techniques

2020 ◽  
Vol 234 (4) ◽  
pp. 398-411 ◽  
Author(s):  
Vishal Gupta ◽  
Ravinder Pal Singh ◽  
Pulak M Pandey ◽  
Ravi Gupta
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Rotational Speed ◽  
Experimental Investigations ◽  
Drilling Process ◽  
Bone Drilling ◽  
Thermal Necrosis ◽  
Study Results ◽  
Drill Diameter

In orthopedic and trauma surgical operations, drilling of bone is one of the commonly used procedures performed in hospitals and is a clinical practice for fixing the fractured parts of human bones. Force, torque and temperature play a significant role during the bone drilling and decide the stability of the medical implants. Therefore, it is necessary to minimize force, torque and temperature while drilling to avoid the thermal necrosis and osteosynthesis. This study focused on studying the influence of various types of bone drilling parameters (rotational speed, feed rate, drill diameter and ultrasonic amplitude), tools (solid tool, hollow tool and conventional twist drill bit) and techniques (conventional surgical drilling, rotary ultrasonic bone drilling and rotary bone drilling) on force, torque, temperature and microcracks produced in the drilled surface of the bone. The experimental investigations were conducted on porcine bone samples to perform the comparative study. Results revealed that increasing the diameter of drill tool and feed rate results in the increase in force, torque and temperature, while low rotational speed (500 r/min) generated a low temperature, high cutting force and torque for all types of drilling processes and tools evaluated in this study. Experimental results also revealed that rotary ultrasonic bone drilling with hollow tool generated the lowest cutting force, torque, temperature (<47 °C) and microcracks in the drilled surface of the bone as compared to the other four types of drilling techniques evaluated in this study. Influence of external irrigation technique on temperature was also studied with respect to the rotary ultrasonic bone drilling with a hollow tool, which could eliminate the problem of thermal necrosis. In conclusion, this study revealed that the rotary ultrasonic bone drilling process with hollow tool produced lesser cutting force as compared to rotary bone drilling and conventional surgical drilling for hollow and solid tools. The study also revealed that rotary ultrasonic bone drilling process has the potential to minimize the cutting force, torque and temperature as compared to the conventional surgical drilling for orthopedic surgery.

Effects of rotary ultrasonic bone drilling on cutting force and temperature in the human bones

2020 ◽  
Vol 234 (8) ◽  
pp. 829-842 ◽  
Author(s):  
Ravinder Pal Singh ◽  
Pulak Mohan Pandey ◽  
Chittaranjan Behera ◽  
Asit Ranjan Mridha
Keyword(s):  
Cutting Force ◽  
Temperature Rise ◽  
Feed Rate ◽  
Rotational Speed ◽  
Host Factors ◽  
Drilling Process ◽  
Bone Drilling ◽  
Human Bones ◽  
Significant Difference ◽  
Drill Diameter

Efficacy and outcomes of osteosynthesis depend on various factors including types of injury and repair, host factors, characteristics of implant materials and type of implantation. One of the most important host factors appears to be the extent of bone damage due to the mechanical force and thermal injury which are produced at cutting site during bone drilling. The temperature above the critical temperature (47 °C) produces thermal osteonecrosis in the bones. In the present work, experimental investigations were performed to determine the effect of drilling parameters (rotational speed, feed rate and drill diameter) and techniques (conventional surgical bone drilling and rotary ultrasonic bone drilling) on cutting force and temperature generated during bone drilling. The drilling experiments were performed by a newly developed bone drilling machine on different types of human bones (femur, tibia and fibula) having different biological structure and mechanical behaviour. The bone samples were procured from male cadavers with the age of second to fourth decades. The results revealed that there was a significant difference ( p < 0.05) in cutting force and temperature rise for rotary ultrasonic bone drilling and conventional surgical bone drilling. The cutting force obtained in rotary ultrasonic bone drilling was 30%–40%, whereas temperature generated was 50%–55% lesser than conventional surgical bone drilling process for drilling in all types of bones. It was also found that the cutting force increased with increasing feed rate, drill diameter and decrease in rotational speed, whereas increasing rotational speed, drill diameter and feed rate resulted in higher heat generation during bone drilling. Both the techniques revealed that the axial cutting force and the temperature rise were significantly higher in femur and tibia compared with the fibula for all combinations of process parameters.

Comparison of Conventional and Ultrasonic Drilling on Cutting Force in Porcine and Human Femur

2020 ◽  
Author(s):  
Ravinder Pal Singh ◽  
Pulak Mohan Pandey
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Rotational Speed ◽  
Bone Fractures ◽  
Drilling Process ◽  
Human Beings ◽  
Bone Drilling ◽  
Human Femur ◽  
Ultrasonic Drilling ◽  
Drill Diameter

Abstract Bone fractures are common in human beings, and the surgical operation performed to repair the fractured bone includes the drilling process. Axial cutting force during drilling plays an important role for success in osteosynthesis. Many processes like water jet machining, laser drilling, ultrasonic drilling, two phase drilling and rotary ultrasonic bone drilling (RUBD), have been developed to minimize the cutting force during orthopedic drilling. In the present work, a novel operation theatre compatible ultrasonic assisted rotary bone drilling machine prototype have been designed and fabricated in an attempt to reduce the cutting forces produced during orthopedic drilling. The experimental test were performed on fresh porcine bone and human femur. A comparative study was carried out between RUBD and Conventional drilling (CD), to find out the influence of rotational speed, drilling tool feed rate and drill diameter, on the cutting force produced during the drilling. The study of chip produced in RUBD and CD was also carried out with the help of scanning electron microscopy images. The result obtained by the developed machine showed that the cutting force obtained in human femur was greater (20–25 %) than porcine femur due to its greater hardness and RUBD process produced lower cutting force (20–30 %) than CD for both types of bone. The experimental results showed the increase in cutting force with decreasing rotational speed and increasing feed rate and drill diameter.

Investigation, sensitivity analysis, and multi-objective optimization of effective parameters on temperature and force in robotic drilling cortical bone

2017 ◽  
Vol 231 (11) ◽  
pp. 1012-1024 ◽  
Author(s):  
Vahid Tahmasbi ◽  
Majid Ghoreishi ◽  
Mojtaba Zolfaghari
Keyword(s):  
Sensitivity Analysis ◽  
Feed Rate ◽  
Process Temperature ◽  
Drilling Process ◽  
Drilling Speed ◽  
Multi Objective Optimization ◽  
Bone Drilling ◽  
Multi Objective ◽  
Tool Diameter ◽  
First Time

The bone drilling process is very prominent in orthopedic surgeries and in the repair of bone fractures. It is also very common in dentistry and bone sampling operations. Due to the complexity of bone and the sensitivity of the process, bone drilling is one of the most important and sensitive processes in biomedical engineering. Orthopedic surgeries can be improved using robotic systems and mechatronic tools. The most crucial problem during drilling is an unwanted increase in process temperature (higher than 47 °C), which causes thermal osteonecrosis or cell death and local burning of the bone tissue. Moreover, imposing higher forces to the bone may lead to breaking or cracking and consequently cause serious damage. In this study, a mathematical second-order linear regression model as a function of tool drilling speed, feed rate, tool diameter, and their effective interactions is introduced to predict temperature and force during the bone drilling process. This model can determine the maximum speed of surgery that remains within an acceptable temperature range. Moreover, for the first time, using designed experiments, the bone drilling process was modeled, and the drilling speed, feed rate, and tool diameter were optimized. Then, using response surface methodology and applying a multi-objective optimization, drilling force was minimized to sustain an acceptable temperature range without damaging the bone or the surrounding tissue. In addition, for the first time, Sobol statistical sensitivity analysis is used to ascertain the effect of process input parameters on process temperature and force. The results show that among all effective input parameters, tool rotational speed, feed rate, and tool diameter have the highest influence on process temperature and force, respectively. The behavior of each output parameters with variation in each input parameter is further investigated. Finally, a multi-objective optimization has been performed considering all the aforementioned parameters. This optimization yielded a set of data that can considerably improve orthopedic osteosynthesis outcomes.

scholarly journals Surface Roughness Optimization in Drilling Process Using Response Surface Method (RSM)

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
Mohd Amran ◽  
Siti Salmah ◽  
Mohd Sanusi ◽  
Mohd Yuhazri ◽  
Noraiham Mohamad ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Feed Rate ◽  
Spindle Speed ◽  
Drilling Process ◽  
Surface Method ◽  
Drilling Parameters ◽  
Drill Diameter

This paper presents the effect of drilling parameters on surface roughness and surface appearance by applying response surface method (RSM). The mathematical model for correlating the interactions of drilling parameters such as spindle speed, feed rate and drill diameter on surface roughness was developed. RSM methodology was used as it is a technique that most practical and effective way to develop a mathematical model. In addition, this method also can reduce trial and error in experiment. Since the number of factors are three; spindle speed, feed rate and drill diameter, by applying RSM the total numbers of experiment involved are 20 experimental observations. From the experimental result, it is found that the minimum surface roughness on the hole was 1.06 mm from combination of 2000 rpm spindle speed, 78 mm/min feed rate and 2.5 mm drill diameter. While the maximum surface roughness 2.59 mm was the combination of 250 rpm spindle speed, 153 mm/min feed rate and 3.5 mm drill diameter. A mathematical equation was developed with percentage of error are 0% to 29%. Thus, from the result we understand that to find the smooth surface in drilling process, it needs higher spindle speed with lower feed rate and smaller diameter.

scholarly journals Quantitative Analysis of Force and Torque in Bone Drilling

2017 ◽  
Vol 14 (1) ◽  
pp. 39 ◽  
Author(s):  
K. Alam ◽  
R. Muhammad ◽  
A. Shamsuzzoha ◽  
A. AlYahmadi ◽  
N. Ahmed
Keyword(s):  
Feed Rate ◽  
Scientific Information ◽  
Cutting Parameters ◽  
Drilling Process ◽  
Drilling Speed ◽  
Bone Drilling ◽  
Drilling Force ◽  
Prediction And Control ◽  
Lower Torque ◽  
And Control

Bone drilling is an important and the most frequent operation in orthopaedics and other bone surgical procedures. Prediction and control of drilling force and torque are critical to safe and efficient surgeries. This paper studies the drilling force and torque arising from bone drilling process. Drilling parameters such as drilling speed, feed rate, drill size and drill condition (sharp and worn) were changed to measure the force and torque in the direction of the drill penetration. Experimental results demonstrated lower drilling force using a sharp drill compared to a worn drill for similar drilling conditions. Contrary to the drilling force, lower torque was measured using a worn drill compared to a sharp drill. The drilling force was found to decrease with increase in drill speed and increased with rise in the feed rate using both types of drills. A linear drop in drilling torque was measured with increase in drilling speed. This study provided scientific information to orthopaedic surgeons and technicians to use appropriate surgical drill and cutting parameters to avoid overstressing of the bone tissue and drill breakage during drilling operations. 

Study on the Prediction of Drilling Forces on Cortical Bone Based on Finite Element Simulation

2013 ◽  
Vol 589-590 ◽  
pp. 157-162
Author(s):  
Ya Hui Hu ◽  
Qing Yun Zhang ◽  
Xiao Yu Yue
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Feed Rate ◽  
Orthogonal Experiment ◽  
Element Model ◽  
Drilling Speed ◽  
Drilling Force ◽  
Drill Diameter ◽  
Potential Damage ◽  
Set Up

The changes of drilling forces during bone drilling provide a useful index for evaluating the risk of potential damage to the bone. The aim of the work is that an elastic-plastic dynamic finite element model is used to simulate the process of a drill bit drilling through the bone. The finite element model was set up in the Abaqus6.11; the prediction model of the drilling force was gotten by using the regression orthogonal experiment and data processing software Matlab7.0. Diverse values of drilling speed, feed rate and drill diameter are important factors which will lead to changes in the drilling forces. By controlling the drilling parameters can obtain the optimal drilling force. The results show that the diameter has the greatest influence on the drilling force, the drilling speed the second, the feed rate the last.

scholarly journals A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Qiang Fang ◽  
Ze-Min Pan ◽  
Bing Han ◽  
Shao-Hua Fei ◽  
Guan-Hua Xu ◽  
...  
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Reinforced Plastics ◽  
Orbital Drilling ◽  
Drilling Parameters ◽  
Drilling Operations ◽  
Machining Properties

Drilling carbon fiber reinforced plastics and titanium (CFRP/Ti) stacks is one of the most important activities in aircraft assembly. It is favorable to use different drilling parameters for each layer due to their dissimilar machining properties. However, large aircraft parts with changing profiles lead to variation of thickness along the profiles, which makes it challenging to adapt the cutting parameters for different materials being drilled. This paper proposes a force sensorless method based on cutting force observer for monitoring the thrust force and identifying the drilling material during the drilling process. The cutting force observer, which is the combination of an adaptive disturbance observer and friction force model, is used to estimate the thrust force. An in-process algorithm is developed to monitor the variation of the thrust force for detecting the stack interface between the CFRP and titanium materials. Robotic orbital drilling experiments have been conducted on CFRP/Ti stacks. The estimate error of the cutting force observer was less than 13%, and the stack interface was detected in 0.25 s (or 0.05 mm) before or after the tool transited it. The results show that the proposed method can successfully detect the CFRP/Ti stack interface for the cutting parameters adaptation.

Defect evaluation of the honeycomb structures formed during the drilling process

2019 ◽  
Vol 29 (3) ◽  
pp. 454-466
Author(s):  
P Ghabezi ◽  
M Farahani ◽  
A Shahmirzaloo ◽  
H Ghorbani ◽  
NM Harrison
Keyword(s):  
Feed Rate ◽  
Cutting Speed ◽  
Drilling Process ◽  
Delamination Factor ◽  
Drilling Parameters ◽  
Principal Factors ◽  
Novel Method ◽  
Full Factorial Experimental Design ◽  
Tool Diameter ◽  
Full Factorial

In this paper, a comprehensive experimental investigation was carried out to precisely characterize the delamination and uncut fiber in the drilling process. A digital imaging procedure was developed in order to calculate the damage resulted from the drilling process. A novel method is proposed in this article based on image intensity to verify the obtained results. A full factorial experimental design was performed to evaluate the importance of the drilling parameters. Among other process parameters, feed rate, cutting speed, and tool diameter are the principal factors responsible for the delamination damage size during the drilling. The drilling process was assessed based on two proposed incurred damage factors, specifically the delamination factor and uncut fiber factor. Experimental results demonstrated that the feed rate was the paramount parameter for both delamination and uncut fiber factors. It was observed that both factors increased with an increase in the feed rate. Additionally, by increasing the tool diameter, the delamination and uncut fiber factors significantly increase. The effects of the cutting speed on damage factors were not linear. The minimum delamination factor and uncut fiber factor were obtained at the cutting speed of 1500 and 2500 r/min, respectively.

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