Parameters affecting mechanical and thermal responses in bone drilling: A review

On the importance of precision in cortical bone drilling: Integrating experimental validation and computational modeling

Background

Cortical bone drilling is integral to orthopedic and dental surgeries, yet challenges such as thermal necrosis persist. Previous finite element (FE) models may overlook critical parameters, impacting accuracy. This study aims to integrate experimental and computational approaches to predict essential parameters-initial temperature, point angle, and spindle speed-enhancing precision in cortical bone drilling.

Methods

Bovine cortical samples were utilized to systematically investigate the impact of four independent parameters on maximum temperature (MT) and maximum thrust force (MTF). Parameters included drill bit initial temperature (IT), diameter, point angle, and spindle speed (225-2700 rpm, feed rate 0.5-3 mm/s). Experimental procedures involved an orthopedic handpiece with titanium drill bits. DEFORM-3D V6.02 facilitated FE simulation, with the validated model developed for the second stage of the drilling process.

Results

The validated model highlighted the significant impact of drill bit IT on MT, predicting a 26.14 % decrease in final bone temperature as IT decreased from 25 to 5 °C. Increasing the point angle from 70 to 120° resulted in a 13.1 % MT increase and a 26.9 % decrease in MTF. Spindle speed variations exhibited a 48.3 % temperature increase and an 82.8 % MTF decrease.

Conclusions

Integrating experimental validation and computational modeling offers a comprehensive approach to predict drilling parameters. Precision in cortical bone drilling can be optimized by selecting specific parameters, including lower drill bit IT, smaller point angles, and controlled spindle speeds. This optimization reduces the risk of bone necrosis and thermal damage, thereby enhancing surgical outcomes.

Design and performance analysis of low damage anti-skid crescent drills for bone drilling

BACKGROUND

With orthopedic surgery increasing year on year, the main challenges in bone drilling are thermal damage, mechanical damage, and drill skid. The need for new orthopedic drills that improve the quality of surgery is becoming more and more urgent.

METHODS

Here, we report the skidding mechanism of drills at a wide range of inclination angle and propose two crescent drills (CDTI and CDTII). The anti-skid performance and drilling damage of the crescent drills were analyzed for the first time. Inclined bone drilling experiments were carried out with crescent drills and twist drills and real-time drilling forces and temperatures were collected.

RESULTS

The crescent drills are significantly better than the twist drill in terms of anti-skid, reducing skidding forces, thrust forces and temperature. The highest temperature is generated close to the upper surface of the workpiece rather than at the hole exit. Finally, the longer crescent edge with a small and negative polar angle increases the rake angle of the cutting edge and reduces thrust forces but increases skidding force and temperature. This study can promote the development of high-quality orthopedic surgery and the development of new bone drilling tools.

CONCLUSION

The crescent drills did not skid and caused little drilling damage. In comparison, the CDTI performs better in reducing the skidding force, while the CDTII performs better in reducing the thrust force.

Assessment of Thermal Osteonecrosis during Bone Drilling Using a Three-Dimensional Finite Element Model

Bone drilling is a common procedure used to create pilot holes for inserting screws to secure implants for fracture fixation. However, this process can increase bone temperature and the excessive heat can lead to cell death and thermal osteonecrosis, potentially causing early fixation failure or complications. We applied a three-dimensional dynamic elastoplastic finite element model to evaluate the propagation and distribution of heat during bone drilling and assess the thermally affected zone (TAZ) that may lead to thermal necrosis. This model investigates the parameters influencing bone temperature during bone drilling, including drill diameter, rotational speed, feed force, and predrilled hole. The results indicate that our FE model is sufficiently accurate in predicting the temperature rise effect during bone drilling. The maximum temperature decreases exponentially with radial distance. When the feed forces are 40 and 60 N, the maximum temperature does not exceed 45 °C. However, with feed forces of 10 and 20 N, both the maximum temperatures exceed 45 °C within a radial distance of 0.2 mm, indicating a high-risk zone for potential thermal osteonecrosis. With the two-stage drilling procedure, where a 2.5 mm pilot hole is predrilled, the maximum temperature can be reduced by 14 °C. This suggests that higher feed force and rotational speed and/or using a two-stage drilling process could mitigate bone temperature elevation and reduce the risk of thermal osteonecrosis during bone drilling.

Ultrasonic-assisted drilling of cortical and cancellous bone in a comparative point of view

Background

During bone drilling, a common procedure in clinical surgeries, excessive heat generation and drilling force can cause damage to bone tissue, potentially leading to failure of implants and fixation screws or delayed healing. With this in mind, the aim of this study was to evaluate the efficiency of ultrasonic-assisted drilling compared to conventional drilling as a potential method for bone drilling.

Methods

This study examined optimal drilling parameters based on previous findings and investigated both cortical and cancellous bone. In addition to evaluating drilling force and temperature elevation, the effects of these factors on osteonecrosis and micro-crack formation were explored in ultrasonic-assisted and conventional drilling through histopathological assessment and microscopic imaging. To this end, three drilling speeds and two drilling feed-rates were considered as variables in the in vitro experiments. Furthermore, numerical modeling provided insight into temperature distribution during the drilling process in both methods and compared three different vibration amplitudes.

Results

Although temperature elevations were lower in the conventional drilling, ultrasonic-assisted drilling produced less drilling force. Additionally, the latter method resulted in smaller osteonecrosis regions and did not produce micro-cracks in cortical bone or structural damage in cancellous bone.

Conclusions

Ultrasonic-assisted drilling, which caused less damage to bone tissue in both cortical and cancellous bone, was comparatively more advantageous. Notably, this study demonstrated that to determine the superiority of one method over the other, we cannot rely solely on temperature variation results. Instead, we must consider the cumulative effect of both temperature elevation and drilling force.

Correlation between intraosseous thermal change and drilling impulse data during osteotomy within autonomous dental implant robotic system: An in vitro study

OBJECTIVES

This study aims at examining the correlation of intraosseous temperature change with drilling impulse data during osteotomy and establishing real-time temperature prediction models.

MATERIALS AND METHODS

A combination of in vitro bovine rib model and Autonomous Dental Implant Robotic System (ADIR) was set up, in which intraosseous temperature and drilling impulse data were measured using an infrared camera and a six-axis force/torque sensor respectively. A total of 800 drills with different parameters (e.g., drill diameter, drill wear, drilling speed, and thickness of cortical bone) were experimented, along with an independent test set of 200 drills. Pearson correlation analysis was done for linear relationship. Four machining learning (ML) algorithms (e.g., support vector regression [SVR], ridge regression [RR], extreme gradient boosting [XGboost], and artificial neural network [ANN]) were run for building prediction models.

RESULTS

By incorporating different parameters, it was found that lower drilling speed, smaller drill diameter, more severe wear, and thicker cortical bone were associated with higher intraosseous temperature changes and longer time exposure and were accompanied with alterations in drilling impulse data. Pearson correlation analysis further identified highly linear correlation between drilling impulse data and thermal changes. Finally, four ML prediction models were established, among which XGboost model showed the best performance with the minimum error measurements in test set.

CONCLUSION

The proof-of-concept study highlighted close correlation of drilling impulse data with intraosseous temperature change during osteotomy. The ML prediction models may inspire future improvement on prevention of thermal bone injury and intelligent design of robot-assisted implant surgery.

Temperature change during orthopedic drilling procedures: An experimental surgical internal fixation simulation study

Background

The purpose of this experimental surgical internal fixation simulation study was to analyze four drilling parameters as a whole, use a thermal camera to observe the temperature, and then determine how these parameters were related to temperature.

Methods

Four separate experimental models were examined in terms of the impacts of four drilling parameters, defined as the drill, drill bit diameter, drill bit design, and the material drilled during drilling procedures, on temperature.

Results

The temperature was observed to be affected by the drill used, a change in the drill bit diameter, drill bit design, and the characteristics of the material drilled (p < 0.041, p < 0.001, p < 0.001, and p < 0.001, respectively). The speeds of the four drills used were measured as 558 rpm, 1385 rpm, 930 rpm, and 1490 rpm.

Conclusion

The findings of the present research demonstrated that the four parameters investigated were related to the temperature formed during drilling. Of the parameters examined, the parameter which increased the temperature the most was a change in the drill bit diameter.

Biomechanical comparison of compact versus standard flute drill bits, and interlocking versus buttress thread self-tapping cortical bone screws in cadaveric equine third metacarpal condyle

OBJECTIVES

To compare (1) performance of compact versus standard flute drill bits, (2) screw insertion properties and (3) pullout variables between interlocking thread (ITS) and buttress thread (BTS) self-tapping screws in third metacarpi.

STUDY DESIGN

In vitro experimental study.

SAMPLE POPULATION

Paired third metacarpi from 11 Thoroughbreds aged 2-4 years.

METHODS

Screws were inserted into the lateral condylar fossae following bone preparation using the respective drill bit for each screw type. Screw pullout was achieved using a mechanical testing system. Density and porosity of bone surrounding screw holes was measured with microcomputed tomography following each pullout test. Drilling, screw insertion and pullout variables were compared between drill bit and screw types using repeated measures ANOVA. Linear regression analyses were used to characterize relationships between bone tissue properties and drill bit and screw outcomes.

RESULTS

Maximum torque power spectral density (PSD) was lower for compact flute drill bits. Insertion torque was 50% higher for ITS. BTS had 33% greater preyield stiffness and 7% greater mean yield force. Bone tissue properties affected measured variables similarly for both screw and drill bit types.

CONCLUSIONS

Lower torque PSD may increase durability of the compact flute drill bit. ITS had greater insertional torque, which may reflect greater bone engagement. BTS had greater resistance to axial pullout forces.

CLINICAL SIGNIFICANCE

Metacarpal bone provides a simple model for comparison of drill bit and screw designs. Use of ITS to repair equine fractures subject to predominantly tensile forces is not justified based on the results of this study.

Effect of drill quality on biological damage in bone drilling

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.

Investigation of transient machining in the cortical bone drilling process by conventional and axial vibration-assisted drilling methods

A temperature exceeding the safety threshold and excessive drilling force occurring during bone drilling may lead to irreversible damage to bone tissue and postoperative complications. Previous studies have shown that vibration-assisted drilling methods could have lower temperatures and drilling forces than those of the conventional drilling method; we hypothesized that the main reason for these reductions stems from the differences in the transient machining processes between conventional and vibration-assisted drilling methods. To investigate these differences, comparative experiments and two-dimensional finite element models were performed and developed. The differences in the transient machining processes were verified by experimentation and clearly exhibited by the finite element models. Compared with the steady cutting process that produced continuous-spiral chips in the conventional drilling method, transient machining in the low-frequency vibration-assisted drilling method was a periodically dynamic cutting-separation process that produced uniform petal chips with specific settings of drilling and vibration parameters. Moreover, the transient machining process in the ultrasonic vibration-assisted drilling method was transformed into a combined action with high-speed impact and negative rake angle cutting processes; this action produced a large proportion of powdery chips. Therefore, it could be concluded that the superposed axial vibration significantly changed the transient machining process and radically changed the mechanical state and thermal environment; these changes were the main reason for the apparent differences in the drilling performance levels.

Tool parameters to minimize temperature changes in bone drilling

BACKGROUND

Drilling is a common technique used in orthopedic surgery procedures but causes increases in temperature that can lead to cell damage and death. The extent of this depends largely on the magnitude of the increase in temperature. The commonly accepted limit to prevent osteonecrosis is less than 47 °C for 60 s. There is controversy when it comes to the optimal drilling parameters that limit temperature increases and cell death. In addition to this, less research has been done on the drilling effects in the osteochondral area of joints. Osteochondral tissue damage can interfere with the daily lives of patients and if severe enough will need to be treated. We hypothesize that increasing tool speed and drill bit size will increase temperature that could be above the osteonecrosis limit.

METHODS

Ex-vivo experiments were conducted on porcine shoulder joints that tested the thermal effects of different tool speeds and drill bit sizes. A thermal camera was used to record and measure real time temperature changes while drilling. Three drill bit sizes and five tool speeds were used. Statistical analyses includes Welch's ANOVA with Games-Howell Post Hoc analyses, multivariate linear regression, and surface response regression were used to explore the association of tool speeds and drill bit size on temperature.

RESULTS AND CONCLUSIONS

All the tool speed and drill bit size combinations lead to an increase in temperature that were under the commonly accepted limit. The highest temperature reached was 44 °C with a tool speed of 1150 RPM and 3070 RPM and drill bit size 5.159 mm. It was found that increasing the tool speed increased the temperature change and increasing the drill bit size increased the temperature change.

Bone cutting efficiency and heat generation using a traditional fluted Burr and a novel fluteless resurfacing tool

BACKGROUND

Powered instrumentation is often used for bone preparation and/or removal in many orthopaedic procedures but does risk thermogenesis. This study compares biomechanical properties of a fluted burr and a novel fluteless resurfacing tool.

METHODS

Twenty cadaveric metatarsals were tested with four predetermined cutting forces to evaluate heat generation and cutting rate for the fluted burr and fluteless resurfacing tool over 40 s or until a depth of 4 mm was reached. Cutting rate was calculated from displacement transducer data. Heat generation was measured by thermocouples placed in the bone adjacent to the burring site. Assuming a body temperature of 37 °C, a 10 °C increase in heat was used as the threshold of inducing osteonecrosis.

FINDINGS

At 1.0 N and 1.7 N, the thermal osteonecrosis threshold was reached at comparable times between burrs, while the bone removed by the resurfacing tool was on average five times greater than fluted burr at 1.0 N and over twice as great at 1.7 N. Statistical analysis of these common cutting forces showed the resurfacing tool had significantly higher cutting rates (P < 0.01). As a result, the fluted burr produced higher temperatures for the same amount of bone removal (P < 0.01).

INTERPRETATION

In a cadaveric study, the fluteless resurfacing tool demonstrated higher bone cutting rates and lower heat generation for the same amount of bone removed than a traditional fluted burr.

Heat Accumulation in Implant Inter-Osteotomy Areas-An Experimental In Vitro Study

To examine the influence of the distance between adjacent implant osteotomies on heat accumulation in the inter-osteotomy area, two experimental groups with 15 pairs of osteotomies in Type II polyurethane blocks were compared: 7 mm inter-osteotomy separations (Group A, n = 15) and 14 mm inter-osteotomy separations (Group B, n = 15). An infrared thermographic analysis of thermal changes in the inter-osteotomy area was completed. A one-way analysis of variance (ANOVA) and Fisher post-test were used to determine group differences. Higher temperatures were recorded in Group A at the coronal and middle levels compared to the apical level in both groups. The temperature reached max temperatures at T80s and T100s. In Group A, the threshold for thermal necrosis was exceeded. Meanwhile, Group B did not reach the threshold for thermal necrosis. Preparing adjacent implant osteotomies in dense bone with a 7 mm separation between their centers increases the temperature in the inter-osteotomy area, exceeding the threshold for bone thermal necrosis; meanwhile, increasing the distance between osteotomies reduces the thermal accumulation and the risk for thermal necrosis.

General Considerations About Foot and Ankle Arthrodesis. Any Way to Improve Our Results?

Nonunion and adjacent joint osteoarthritis (OA) are known complications after a fusion procedure, and foot and ankle surgeons are commonly exposed to such disabling complications. Determining who is at risk of developing nonunion is essential to reducing nonunion rates and improving patient outcomes. Several evidenced-based modifiable risk factors related to adverse outcomes after foot and ankle arthrodesis have been identified. Patient-related risk factors that can be improved before surgery include smoking cessation, good diabetic control (HbAc1 <7%) and vitamin D supplementation. Intraoperatively, using less invasive techniques, avoiding joint preparation with power tools, using bone grafts or orthobiologics in more complex cases, high-risk patients, nonunion revision surgeries, and filling in bone voids at the arthrodesis site should be considered. Postoperatively, pain management with NSAIDs should be limited to a short period (<2 weeks) and avoided in high-risk patients. Furthermore, early postoperative weight-bearing has shown to be beneficial, and it does not seem to increase postoperative complications. The incidence of surrounding joint OA after foot and ankle fusion seems to increase progressively with time. Owing to its progression and high probability of being symptomatic, patients must be informed consequently, as they may require additional joint fusions, resulting in further loss of ankle/foot motion. In patients with symptomatic adjacent joint OA and unsatisfactory results after an ankle arthrodesis, conversion to total ankle arthroplasty (TAA) has become a potential option in managing these complex and challenging situations.

Understanding the thrust force evolution and primary stability for dental implantation – An in-vitro experimental investigation

The dental implant is challenging due to the unstable quality of the surrounding bone. This study aimed to explore the feasibility of using thrust force characteristics to identify different bone types and the influencing mechanisms of spindle speed and feed rate on primary stability of dental implants through in-vitro experiments. 13 groups of osteotomy experiments were performed on mandibles and maxillae of pigs with different bone types (I, II, and III) under different spindle speeds (600 and 800 rpm) and feed rates (20 and 60 mm/min). The thrust force evolution under different conditions was extracted and analysed to elaborate the distribution and thickness of the cortical and trabecular bone layers on different bone types. Dental implant placements were performed, and corresponding primary stabilities were obtained. Furthermore, histologic observation was conducted to reveal the bone/implant contact morphology. From the results, the amplitude and trend of thrust force show a regular variation during drilling different bone types. The highly dynamic information of thrust force can be analysed to characterise the distribution and thickness of the cortical and trabecular bone layers, hence effectively detecting different bone types. Since a lower feed rate and resulting bone temperature elevation lead to more thermal damages, primary stability decreases with the decrease of feed rate. Spindle speed has no significant effect. This study establishes a more in-depth understanding into the thrust force evolution and also provide a clinical option for reducing the complexity of bone type and drilling parameters determination in osteotomy.

Prediction of temperature elevation in rotary ultrasonic bone drilling using machine learning models: An in-vitro experimental study

Bone drilling is frequently used during orthopaedic surgeries to treat the fractured part of the bone. A major concern for surgeons is the increase in temperature during real-time orthopaedic bone drilling. The temperature elevation at the bone-tool interface may cause permanent death of regenerative soft tissues and cause thermal osteonecrosis. A robust predictive machine-learning model is suggested in this in-vitro research for monitoring temperature rise during surgery. The objective of the present work is to introduce different machine learning algorithms for predicting temperature elevations in rotary ultrasonic bone drilling. Different machine-learning models were compared with the standard response surface methodology. The performance and accuracy of different predictive models were compared at different error metrics. It was witnessed that support vector machines performed the best for predicting the change in temperature in comparison to other predictive models. Moreover, the error metrics for statistical response surface methodology analysis were comparatively higher than the machine learning algorithms. By using machine learning models, it is possible to predict temperature rise during bone drilling.

K-wire pullout strength in hand surgery: Impact of diameter, threading length and drilling speed

INTRODUCTION

The aim of the present study was to assess the impact, combined and in interaction, of diameter, threading length and drilling speed on K-wire pullout strength in a synthetic model of a hand bone.

MATERIAL AND METHODS

The material comprised Sawbones® (20 ×20×50mm), K-wires (diameter 1.2mm, 1.5mm, 1.8mm; threading 0mm, 5mm, 10mm, 15mm), a universal chuck with T handle and a drill (speed 0, 320, 500, 830, 1,290rpm), and tensile testing machine and a digital decision aid. The Sawbones® were drilled, varying diameter, threading and speed. The Statistical Design of Experiments (SDOE) methodology enabled the number of trials to be reduced from 300 to 70. Tensile tests at 1mm/s was imposed on the K-wire up to pullout (pullout strength).

RESULTS

There was no interaction between threading length and diameter effects or between drilling speed and diameter effects, but a strong interaction between drilling speed and threading length effects.

CONCLUSION

Before using K-wires for internal fixation in wrist or hand fracture, the surgeon has to select their characteristics, optimal holding power being theoretically ensured by large diameter wires with long threading inserted by a high-speed drill.

LEVEL OF EVIDENCE

I, experimental study.

An analytical and numerical approach to the determination of thermal necrosis in cortical bone drilling

In the process of repairing fractures in the bone region with orthopedic injuries, the application of supporting and strengthening the bone tissue with screws, wires, rods, and plates is a widely preferred internal fixation method. In this treatment process, it is necessary to drill the bone tissue to fix the screws. Due to the heat generated in the drilling process, mechanical and thermal damage occurs in the bone tissue. In this study, it is focused that the effect of different cutting conditions on the temperature distribution and necrosis zones in the drilling of human cortical bone. In this context, by selecting variable drill geometry (diameter, point angle, and helix angle) and variable cutting parameters (cutting speed and feed rate), temperature distribution and necrosis zones were investigated with finite element analyses and analytical calculations. When the findings were evaluated, it was understood that drill diameter and cutting speed did not have a significant effect on temperatures and necrosis zone at low cutting speeds. At high cutting speeds, it was observed that the feed rate and drill point angle had an indeterminate effect on the temperatures. The lowest temperature values were obtained at cutting speed of 750 rpm and a feed rate of 0.1 mm/rev for low cutting speeds, and cutting speed of 1500 rpm, helix angle of 10° and drill bit diameter of 2 mm for high cutting speeds. The narrowest necrosis zones were obtained at cutting speed of 250 rpm and feed rate of 0.1 mm/rev for both drill diameters. As a result, the effects of different drill geometry and cutting parameters were determined in order to obtain low temperature distribution and narrow necrosis zone in cortical bone drilling.

Concentrations of co-administered vancomycin and meropenem in the internal dead space of a cannulated screw and in cancellous bone adjacent to the screw - Evaluated by microdialysis in a porcine model

BACKGROUND

Cannulated screws are often used in the management of open lower extremity fractures. These fractures exhibit broad contamination profiles, necessitating empirical Gram-positive and Gram-negative antibiotic coverage. To ensure full antibiotic protection of the cannulated screw and the bone tissue, it is generally accepted that target tissue antibiotic concentrations, as a minimum, reach and remain above relevant epidemiological cut-off minimal inhibitory concentrations (T>MIC) for a sufficient amount of time.

METHODS

8 female pigs were included. Microdialysis catheters were placed in the internal dead space of a cannulated screw placed in tibial cancellous bone, in tibial cancellous bone adjacent to the screw (mean distance to the screw: 3 mm), and in cancellous bone on the contralateral tibia. Following single-dose simultaneous intravenous administrations of vancomycin (1000 mg) and meropenem (1000 mg), microdialysates and plasma were dynamically sampled over 8 h. The applied MIC targets ranged from 1 to 4 µg/mL for vancomycin and 0.125-2 µg/mL for meropenem RESULTS: For both drugs, and for all MIC targets investigated (except for the high vancomycin target: 4 µg/mL), the internal dead space of the cannulated screw had the shortest T>MIC. At the low MIC targets T>MIC ranged between 88 and 449 min across sampling sites for vancomycin (1 µg/mL), and 148-406 min for meropenem (0.125 µg/mL). For the high MIC targets, T>MIC ranged between 3 and 446 min for vancomycin (4 μg/mL) and 17-181 min for meropenem (2 μg/mL). Vancomycin displayed longer T>MIC (2 and 4 μg/mL), higher area under the concentration time curve (AUC_0-last) and peak drug concentration in the proximal tibial cancellous bone without a screw nearby. For meropenem, only the cancellous bone AUC_0-last was significantly higher on the side with no screw.

CONCLUSION

We found short T>MIC, particularly for the high MIC targets for vancomycin and meropenem, both inside the cannulated screw and in cancellous bone adjacent to the screw. The presence of a cannulated screw impaired the penetration of especially vancomycin into cancellous bone adjacent to the screw. More aggressive or different vancomycin and meropenem approaches may be considered to encompass contaminating differences and to ensure a theoretically more sufficient antibiotic protection of cannulated screws when used in the management of open lower extremity fractures.

The effects of multiple drilling of a bone with the same drill bit: thermal and force analysis

Repeated use of the same drill bit during drilling wears off the cutting edges, which can lead to a significant increase in heat as a result of friction, which is harmful to a bone above 55 °C. Few previous studies have examined the effects of using the same drill bit several times, on temperature. The objective of this study was to determine the effect of each drilling on temperature and force. 72 trials were performed. A total of 24 stainless steel drill bits of ∅3.2 mm were used to drill bovine bone samples. Each drill bit was used at least 3 times. T thermocouples were used to measure temperatures during each drilling test. Possible correlations of cutting parameters were studied. Tests were performed on a test rig measuring forces and temperatures during drilling. Effects of spindle speed (N), feed rate (V_f), and several trials (E) on temperature and forces were measured. Images of the drill bits were analyzed by digital microscopy before and after the drilling series for signs of wear. Temperatures increased significantly from E₁ to E₃. They decreased moderately with V_f. The best cutting conditions were at N = 200 rpm for V_f = 60 mm/min and N = 100 rpm for V_f = 30 mm/min drilling. At N > 200 rpm, they were very high. Temperature rise is significantly related to number of drilling (E), spindle speed (N), and inversely to feed rate (V_f). Analysis of images by digital microscopy confirmed drill bits wearing off, following the number of trials.

Parametric study of bone drilling by the Kirschner wire

In order to improve the quality and reduce mechanical damage during bone drilling in surgeries, the three key parameters in drilling by the Kirschner wire are experimentally studied based on the response surface method (RSM). And through response surface analysis, a predictive model of each factor and response value is established. The experimental results found that when the beveled plane angle Φ = 10°, the rotational speed n = 1200 rpm, and the feed speed v_f = 20 mm/min. Not only the drilling force is minimized, the delamination coefficient and the height of the hole exit burr are also the minimum. Therefore, the smaller bevel angle, the feed speed and the higher rotation speed can effectively reduce the drilling force, the delamination factor and the height of the hole exit burr, and significantly improve the drilling quality.

Design of a self-centring drill bit for orthopaedic surgery: A systematic comparison of the drilling performance

Bone drilling is an indispensable and demanding operation among many orthopaedic operations. A dedicated drill bit that can achieve low-trauma and self-centring drilling is in urgent need. In this study, a three-step orthopaedic low-traumatic drill bit design was proposed. In order to evaluate the drilling performance of the proposed drill, comprehensive comparison tests were carried out with various commercial medical drills in terms of skiving force, thrust force, temperature rise, and surface quality. The experimental results show that the proposed three-step drill design with the optimal point angle, a small chisel edge, transition arc and web thinning can obtain lower and more stable thrust force, slighter bending force, smaller temperature rise, and higher hole quality compared with the commercial drill bits. The proposed drill shows satisfactory drilling performance and has great application potential in clinical surgery.

Effect of repeated use of an implant handpiece on an output torque: An in-vitro study

PURPOSE

This study aimed to evaluate the effect of repeated use of an implant handpiece under an implant placement torque (35 Ncm) and overloading torque condition (50 Ncm) on an output torque.

MATERIALS AND METHODS

Two types of implant handpiece systems (Surgicpro/X-DSG20L [NSK, Kanuma, Japan] and SIP20/CRB46LN [SAESHIN, Daegu, South Korea]) were used. The output torque was measured using a digital torque gauge. The height and angle (x, y, and z axes) of the digital torque gauge and implant handpiece were adjusted through a jig for passive connection. The experiment was conducted under the setting torque value of 35 Ncm (implant placement torque) and 50 Ncm (overloading torque condition) and 30 times per set; a total of 5 sets were performed (N = 150). For statistical analysis, the difference between the groups was analyzed using the Mann-Whitney U test and the Friedman test was used to confirm the change in output torque (α=.05).

RESULTS

NSK and SAESHIN implant handpieces showed significant differences in output torque results at the setting torques of 35 Ncm and 50 Ncm (P<.001). The type of implant handpiece and repeated use influenced the output torque (P<.001).

CONCLUSION

There may be a difference between the setting torque and actual output torque due to repeated use, and the implant handpiece should be managed and repaired during long-term use. In addition, for successful implant results in dental clinics, the output torque of the implant handpiece system should be checked before implant placement.

Accuracy of guided biopsy of the jawbone in a clinical setting: A retrospective analysis

The aim of this study was to investigate the accuracy of a previously described technique for guided biopsy of osseous pathologies of the jawbone in a clinical setting. The data sets of patients who had undergone guided biopsy procedures were retrospectively examined for accuracy. Digital planning of the biopsies and manufacturing of the tooth-supported drilling template were performed with superimposed cone beam computed tomography and intraoral scans using implant planning software. After a trephine biopsy was taken using the template, the postoperative low-dose cone beam computed tomography was analyzed for accuracy using the planning software with the corresponding (digitally-planned) biopsy cylinder. The mean angular deviation was 4.35 ± 2.5°. The mean depth deviation was -1.40 ± 1.41 mm. Guided biopsy seems to be an alternative to a conventional approach for minimally invasive and highly accurate jawbone biopsy.

Biomechanical Evaluation of Temperature Rising and Applied Force in Controlled Cortical Bone Drilling: an Animal in Vitro Study

Background

The present study was conducted to quantify the relationships between bone drilling process parameters (i.e., feed rate, resting time, exit rate, and drill bit diameter) and drilling outcome parameters (i.e., thrust force and maximum temperature).

Methods

This study utilized 10-cm cortical bovine samples to evaluate the effects of four independent parameters, including drill bit diameters, six different feed rates, three various resting times, and three different exit rates on thrust force and maximum temperature (MT). A total of 28 stainless steel orthopedic drill bits with a diameter of 2.5 and 3.2 mm, as well as an orthopedic handpiece were attached to the 500N load cell and an accurate linear variable differential transformer to obtain forces. Moreover, two k-type thermocouples were utilized to record the temperature-time curve near the drilling site. The data were analyzed using the two-way analysis of variance and post hoc Tukey-Kramer Honest test.

Results

Maximum thrust force (MTF) decreased by almost 230% as the drill bit diameter increased from 2.5 to 3.2 mm in the lowest feed rate. The MTF showed a 335% increase, whereas a decrease of 69% was observed as the feed rates rose from 0.5 to 3 mm/sec. Moreover, the MT decreased to 67% with an increasing exit rate from 1 to 3 mm/sec. Furthermore, a slight increase was observed in MT when the resting time increased from 0 to 2 seconds (P>0.05).

Conclusion

The desired drilling is drilling with lower thrust force and lower final temperature of bone. Increasing feed rate can cause an increase and decline in thrust force and final temperature, respectively. The highest rates of MT were 0.5 and 1 mm/min, and the optimum feed rate would be 1.5 mm/min due to the averaged thrust force. Moreover, the resting time had no significant effects on the final temperature. Attentions to resting time would be useful to provide a more accurate, efficient, and uniform drill hole.

Surgical Drill Bit Design and Thermomechanical Damage in Bone Drilling: A Review

As drilling generates substantial bone thermomechanical damage due to inappropriate cutting tool selection, researchers have proposed various approaches to mitigate this problem. Among these, improving the drill bit design is one of the most feasible and economical solutions. The theory and applications in drill design have been progressing, and research has been published in various fields. However, pieces of information on drill design are dispersed, and no comprehensive review paper focusing on this topic. Systemizing this information is crucial and, therefore, the impetus of this review. Here, we review not only the state-of-the-art in drill bit designs-advances in surgical drill bit design-but also the influences of each drill bit geometries on bone damage. Also, this work provides future directions for this topic and guidelines for designing an improved surgical drill bit. The information in this paper would be useful as a one-stop document for clinicians, engineers, and researchers who require information related to the tool design in bone drilling surgery.

Analysis of machining process and thermal conditions during vibration-assisted cortical bone drilling based on generated bone chip morphologies

When the temperature during bone drilling exceeds the safety threshold, the bone tissue surrounding the drilling site can be irreversibly damaged. To investigate the influence of vibration-assisted drilling (VAD) methods on the temperature increase during bone drilling and the causes for temperature increase, drilling experiments were performed on fresh bovine femur samples. The morphology and granularity distribution of the generated bone chips were innovatively used to directly compare the machining processes and thermal conditions of conventional drilling (CD), low-frequency vibration-assisted drilling (LFVAD), and ultrasonic vibration-assisted drilling (UVAD). The experimental results indicated that LFVAD produced the lowest temperature increase of 31.4°C, whereas UVAD produced the highest temperature increase of 44.1°C with the same drilling parameters. Additionally, the morphologies and granularity distributions of the bone chips significantly differed among these methods. We concluded that the smaller temperature increase in LFVAD was mainly attributed to the improved thermal conditions resulting from the periodic cutting/separation motion and the reliable geometric chip-breaking mechanism. In contrast, the unfavourable thermal conditions of UVAD were caused by the higher applied frequency, which created a significantly larger amount of friction heat. This was the main cause for the highest observed temperature increase, resulting in bone crushing processes that generated additional heat.

Thermographic assessment of heat-induced cellular damage during orthopedic surgery

The heat generated during orthopedic surgery can cause thermal damage to bone cells, leading to cell necrosis, death, and bone resorption. In this study, the drill-exit surface in cortical bone drilling was firstly investigated by infrared thermography to understand the thermal characteristics of bone cutting. In order to mimic the short-term thermal condition of high temperature during surgical cutting, the osteoblasts were exposed to heat shock for short periods of time to investigate the effect of cutting heat on the bone. Necrosis and apoptosis were investigated immediately after heat shock for 2 s, 5 s, and 15 s at 50 °C, 60 °C, 70 °C, and 80 °C, respectively. The cells were then incubated for 4 days at 37 °C and analyzed by fluorescein annexin V-FITC/PI double staining. The temperature and heat-duration were precisely controlled by a novel heating approach. In comparison to the control group (37 °C), immediate necrotic and apoptotic response to heat shock was found in cells exposed to 50 °C for 5 s (11.8%, p<0.05); however, the response was negligible in cells exposed to 50 °C for 2 s. In addition, recovery was found in the group exposed to 50 °C and 60 °C for 2 s (p ≤ 0.05) after incubation for 4 days. Cell damage depends on the magnitude and duration of heat exposure. These findings provide fundamental knowledge for future developments of surgical tool design and cutting methods.

In vivo evaluation of machining forces, torque, and bone quality during skull bone grinding

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.

A New Site Preparation Protocol That Supports Bone Quality Evaluation and Provides Predictable Implant Insertion Torque

When preparing an implant site, clinicians often base their assessment of the bone on subjective tactile and visual cues. This assessment is used to plan the surgical procedure for site preparation, including how many drilling steps will be used. The subjective nature of bone evaluation, consequently, results in poor reproducibility and may lead to under or over preparation of the site. Recently, an unconventional site preparation protocol was developed in which the decision of which instruments to use is dictated by insertion torque of the novel site preparation instrument (OsseoShaper^™, Nobel Biocare AB, Gothenburg, Sweden). The aim of this study was to quantify the correlation of the site preparation torques of the new instrument with bone density and maximum implant insertion torques. In vitro and in vivo data showed strong linear correlation between site preparation torque and density and resulted in reliable implant insertion torques, respectively. From our analysis, we conclude that this new instrument and protocol has the potential to eliminate the need for additional intraoperative bone evaluation and may reduce the risk of inadequate preparation of the site due to the ability to serve as a predictor of the final implant insertion torque.

Experimental study of temperature rise during bone drilling process

An excessive temperature rise during bone drilling processes can result in osteonecrosis or impairment of the osteogenic potential. However, the effect of geometric parameters of the surgical drill bit, drilling process parameters, and the bone type on the temperature rise have not been fully investigated. In this study, thermocouples are introduced to measure the temperature rise, and three experimental designs are utilized separately to investigate the temperature rise with respect to each parameter, identify the effect of important drill geometric parameters and their interaction on the temperature rise, and develop a quadratic model of the temperature rise with respect to process parameters. The results show that the temperature rise can be significantly affected by geometric parameters of the surgical drill bit, drilling process parameters, and the bone type. The effects of the point angle and the interaction between the web thickness and the helix angle on the temperature rise are very significant. The quadratic regression equation obtained using response surface methodology can provide accurate predictions under a wide range of drilling process conditions, and the optimized drilling process parameters are in good agreement with the experimental results.

Measurement and prediction of drilling force in fresh human cadaver mandibles: A pilot study

BACKGROUND

Bone drilling is a vital procedure in implant surgery and dental implant training systems based on virtual reality technology.

PURPOSE

Predict and update drilling force in real time based on a virtual dental implant training system and lay the foundation for realizing force feedback in dental implant training instruments.

MATERIALS AND METHODS

An experimental platform was established to measure the drilling force for human mandibles from donors of different ages. Response surface methodology was applied to analyze the drilling force.

RESULTS

Force regression equations for different age groups were acquired. The order of the effects (from greatest to least) of the drilling parameters on the drilling force was the drill bit diameter, feed rate, and rotational speed. To obtain the minimum force, higher rotational speeds, lower feed rates, and smaller diameters were preferred within the range of commonly used medical reference parameters of bone drilling.

CONCLUSION

The experimental data were confirmed to be scientific for the predicted models of drilling force.

Robots and Tools for Remodeling Bone

The field of robotic surgery has progressed from small teams of researchers repurposing industrial robots, to a competitive and highly innovative subsection of the medical device industry. Surgical robots allow surgeons to perform tasks with greater ease, accuracy, or safety, and fall under one of four levels of autonomy; active, semi-active, passive, and remote manipulator. The increased accuracy afforded by surgical robots has allowed for cementless hip arthroplasty, improved postoperative alignment following knee arthroplasty, and reduced duration of intraoperative fluoroscopy among other benefits. Cutting of bone has historically used tools such as hand saws and drills, with other elaborate cutting tools now used routinely to remodel bone. Improvements in cutting accuracy and additional options for safety and monitoring during surgery give robotic surgeries some advantages over conventional techniques. This article aims to provide an overview of current robots and tools with a common target tissue of bone, proposes a new process for defining the level of autonomy for a surgical robot, and examines future directions in robotic surgery.

An overview of thermal necrosis: present and future

Introduction: Many orthopaedic procedures require drilling of bone, especially fracture repair cases. Bone drilling results in heat generation due to the friction between the bone and the drill bit. A high-level of heat generation kills bone cells. Bone cell death results in resorption of bone around bone screws.Methods: We searched in the literature for data on parameters that influence drilling bone and could lead to thermal necrosis. The points of view of many orthopaedists and neurosurgeons based upon on previous practices and clinical experience are presented.Results: Several potential complications that lead to thermal necrosis are discussed and highlighted.Discussion: Even in the face of growing evidence as to the negative effects of heat induction during drilling, simple and effective methods for monitoring and cooling in real-time are not in widespread usage today. For that purpose, we propose some suggestions for the future of bone drilling, taking note of recent advances in autonomous robotics, intelligent systems and computer simulation techniques.Conclusions: These advances in prevention of thermal necrosis during bone drilling surgery are expected to reduce the risk of patient injury and costs for the health service.

Experimental investigation of the temperature elevation in bone drilling using conventional and vibration-assisted methods

Bone drilling is widely used in orthopaedics for inserting screws and fixing prostheses. Thermal necrosis is one of the major problems that may seriously affect post-operative recovery. Accordingly, this paper mainly focuses on comparing the influences of conventional drilling (CD), ultrasonic vibration-assisted drilling (UVAD) and low-frequency vibration-assisted drilling (LFVAD) methods, and drilling parameters on the temperature elevation in bone drilling process. A full factorial experiment was performed, and the temperatures were measured using an infrared camera. The lowest temperature elevation was obtained by LFVAD compared with CD and UVAD at the same drilling conditions. Setting CD as a reference, the maximum difference between LFVAD and CD was approximately -4 °C, whereas that between UVAD and CD was approximately 16 °C. The temperature elevation increases linearly with the spindle speed and follows an inverted U-shaped curve, with the feed rate having a peak at 40 min/mm in each drilling method. The results were discussed with regard to the features of LFVAD and UVAD. It was expected that the LFVAD could achieve minimal thermal damage and attain better results in the medical bone drilling process.

Experimental Study of Thrust Force and Torque for Drilling Cortical Bone

Excessive drilling forces can result in drill breakage, bone breakthrough, and thermal necrosis during bone drilling process. However, the effect of drilling process parameters, drill geometry parameters, and bone material type on drilling forces have not been fully investigated. Three designs of experiments are introduced separately to study single factor's effect on drilling forces, identify significant geometry parameters and possible interactions for drilling forces, and formulate direct relationship between drilling forces and process parameters. The results show that thrust force and torque are increased with feed rate, drill diameter or web thickness. The effect of spindle speed, point angle, helix angle, and chisel edge angle on drilling forces is complex. The results also show that the drilling forces are affected by bone type significantly, which are highest for bovine cortical bone, and lowest for Sawbones 3401. The levels of significance of geometry parameters are identified and different for thrust force and torque, which can assist new surgical drill development. Quadratic regression equations obtained by response surface methodology can predict thrust force and torque accurately in a wide range of process parameters, which can be used to control drilling conditions for robot assisted surgeries to realize safe drilling.

Drilling of bone: Effect of drill bit geometries on thermal osteonecrosis risk regions

Bone-drilling operation necessitates an accurate and efficient surgical drill bit to minimize thermal damage to the bone. This article provides a methodology for predicting the bone temperature elevation during surgical bone drilling and to gain a better understanding on the influences of the point angle, helix angle and web thickness of the drill bit. The proposed approach utilized the normalized Cockroft-Latham damage criterion to predict material cracking in the drilling process. Drilling simulation software DEFORM-3D is used to approximate the bone temperature elevation corresponding to different drill bit geometries. To validate the simulation results, bone temperature elevations were evaluated by comparison with ex vivo bone-drilling process using bovine femurs. The computational results fit well with the ex vivo experiments with respect to different drill geometries. All the investigated drill bit geometries significantly affect bone temperature rise. It is discovered that the thermal osteonecrosis risk regions could be reduced with a point angle of 110° to 140°, a helix angle of 5° to 30° and a web thickness of 5% to 40%. The drilling simulation could accurately estimate the maximum bone temperature elevation for various surgical drill bit point angles, web thickness and helix angles. Looking into the future, this work will lead to the research and redesign of the optimum surgical drill bit to minimize thermal insult during bone-drilling surgeries.

Recommended Drilling Parameters of Tungsten Carbide Round Drills for the Most Optimal Bone Removals in Oral Surgery

Background

High temperatures during drilling can cause thermal osteonecrosis and abnormal wound healing. According to our best knowledge, a widely accepted recommendation for optimal drilling parameters in routine oral surgery bone removals does not exist.

Purpose

Our aim was to investigate the correlations of different drilling parameters, including axial load and revolution speed on drilling temperatures and preparation times.

Materials and Methods

Standard, 5 mm deep cavities were drilled in 20 PCF (lb/ft³) dens polyurethane blocks with 3 mm (50PCF) cortical layer using new and worn, 3.1mm in diameter tungsten carbide round drills. Worn drills were used in 50 impacted third molar operations before. Axial loads of 3N, 10N, and 25N and speeds of 4.000-8.000-16.000-40.000 revolutions per minute (rpm) were tested. Temperature differences of drilling parameters were calculated by 1-way ANOVA, followed by Tukey's HSD post hoc tests. Time differences and differences among “optimal” and “suboptimal” groups (with the cut-off value of 3°C and 3s) were estimated by Kruskal-Wallis test with pairwise comparisons. P<0.05 was considered significant.

Results

The highest mean temperatures with new and worn drills were 4.64±0.53°C and 6.89±1.16°C, while drilling times varied between 0.16±0.02s and 22.77±5.45s. A 3°C and 3s cut-off value classified drillings significantly to (1) optimal [3N and 8000-16000-40000 rpm or 10N and 4000-8000-16000-40000 rpm] or suboptimal due to (2) high temperatures or (3) long preparation times. Using worn drills, the following parameters should be avoided: 3N with 4.000-8.000 rpm, 10N with 40000 rpm, and 25N at any revolutions.

Discussion

The study extensively mapped the drilling temperatures and preparation times of tungsten carbide round drills. Temperatures did not exceed 10°C during drillings with maximal amount of cooling, as well as the drilling parameters, which kept temperatures and preparation times in the most optimal range which were clearly established.

Optimization of drilling parameters for thermal bone necrosis prevention

BACKGROUND

Bone drilling is a mandatory process in orthopedic surgery to fix the fractured bones. Excessive heat is generated due to the shear deformation of bone and friction energy during the drilling process.

OBJECTIVE

This paper is carried out to optimize the bone drilling parameters to prevent thermal bone necrosis. The main contribution of this work is instead of only consider the influence of rotational speed and feed rate, the effect of tool diameter and drilling hole depth are also incorporated for optimization study.

METHODS

Response surface methodology (RSM) was used to develop a temperature prediction model. Drilling experiments were performed using finite element software DEFORM-3D. Analysis of variance (ANOVA) was conducted to investigate the drilling parameters' effect. Desirability function in RSM was used to determine the optimum combination of drilling parameters.

RESULTS

Results indicated that one applicable combination of drilling parameters could increase the bone temperature by less than 0.03%. To avoid thermal bone necrosis, eight reasonable combinations of drilling parameters were proposed. 3.3∘C residuals between in-vitro experiments and predicted values were demonstrated.

CONCLUSIONS

It is envisaged that finite element simulation with RSM can simplify tedious experimental works and useful in the clinical application to avoid bone necrosis.