Mechanical Properties of a Bone-like Bioceramic-Epoxy-Based Composite Material with Nanocellulose Fibers

Several composite materials are being investigated as reinforcement fillers for surgery simulations. This study presents an artificial composite material with properties similar to those of the human bone, which may be used in surgery simulations. Moreover, considering the potential toxicity of debris generated during sawing, a safe epoxy-based composite material was synthesized using cellulose nanocrystals (CNCs) and bioceramics (i.e., hydroxyapatite, Yttria stabilized zirconia oxide, Zirconia oxide), which were used to mimic the stiffness of human bone. To examine the change in mechanical properties according to the composition, 1, 3, and 5 wt% of CNCs were mixed with 5 wt% of the bioceramics. When CNCs were added at 1 wt%, there was a confirmed change in the non-linear stiffness and ductility. The CNC-added specimen fractured when forming a nano-network around the local CNCs during curing. In contrast, the specimen without CNCs was more densely structured, and combined to form a network of all specimens such that a plastic region could exist. Thus, this study successfully manufactured a material that could mimic longitudinal and transverse characteristics similar to those of real human bone, as well as exhibit mechanical properties such as strength and stiffness. Bioceramics are harmless to the human body, and can be used by controlling the added quantity of CNCs. We expect that this material will be suitable for use in surgery simulations.

Influence of Machining Parameters on Cutting and Chip-Formation Process during Cortical Bone Orthogonal Machining

Cortical bone machining is commonly used in craniofacial surgery. The shaping of bone surfaces requires a precise determination of the process’s complexity due to the cutting tool’s defined or undefined geometry. Therefore, research was carried out to assess the impact of the rake angle (γ), clearance angle and depth of cut (d) on the cortical bone machining process. Analysis was carried out based on the orthogonal cutting in three directions. The cutting tool shape was simplified, and the cutting forces and the chip-formation process were monitored. The highest values of the resultant cutting force and shear force were recorded for γ < 0. The specific cutting force decreases with the increase of d. Cutting in the transverse direction is characterized by the highest values of resultant cutting force and shear force. The coefficient of friction depends primarily on the d and takes a constant value or increases with the increase of γ. The tests showed that the chips are formed in the entire range of d ≥ 0.5 µm and create regular shapes for d ≥ 10 µm. The research novelty confirms that even negative cutting angles guarantee controlled cutting and can find wider application in surgical procedures.

Proposal for a Novel Abrasive Machining Method for Preparing the Surface of Periarticular Tissue during Orthopedic Surgery on Hip Joints

Drilling, cutting, and milling are the most common methods used in orthopedic surgery. However, popular machining methods do not obtain the complex shape of the periarticular tissue surfaces, increasing operation time and patient recovery. This paper reports an attempt to research a novel design of a machining process for surgical procedures. A device using abrasion machining based on mechanical erosion was proposed. Machining uses an undefined geometry of the cutting grains to cut tissue in any direction during oscillatory tool movement. This new concept is based on a cylindrical abrasive device made of brown fused alumina and silicon carbide grains deposited with an epoxy resin binder on the surface of a polyamide shaft. The best results in terms of machining efficiency were obtained for grains of the BFA80 type. Cutting experiments with different values in terms of cutting speed, granulation of the abrasive grains, pressure forces, and machining scope showed that the proposed concept, by developing the shape of the device, allows for penetration of the tissue structure. The research shows the possibility of using the proposed method during periarticular tissue machining.

Analysis and optimization of bone machining for robotic orthopedic surgeries

BACKGROUND

Robot-assisted joint replacement surgery is becoming increasingly more common worldwide, therefore it is important to characterize and improve the bone-cutting mechanics of surgical tools.

METHODS

Linear coefficients relating cutting force and chip thickness were derived for a surgical spindle. The cutting coefficients were integrated into an analytical simulation which calculated cutting forces, torque, and power consumption. An optimization experiment was performed. High speed video was taken at various tool parameter settings.

RESULTS

Varying machining parameters resulted in lower cutting forces. The surgical spindle stalled at the current spindle speed used in surgery, but did not for the new, optimized conditions. Multiple anomalies were identified in the videos that confirmed observations from the cutting force data.

CONCLUSIONS

Improved surgical performance and accuracy were achieved using slower spindle speeds, decreased cutting depth, and increased feed rates, as well as improving motor torque to ensure a smooth cutting process.

Simulation and evaluation of a bone sawing procedure for orthognathic surgery based on an experimental force model

Bone sawing is widely used in orthognathic surgery to correct maxillary deformities. Successful execution of bone sawing requires a high level of dexterity and experience. A virtual reality (VR) surgical simulator can provide a safe, cost-effective, and repeatable training method. In this study, we developed a VR training simulator with haptic functions to simulate bone-sawing force, which was generated by the experimental force model. Ten human skulls were obtained in this study for the determination of surgical bone-sawing force. Using a 5-DOF machining center and a micro-reciprocating saw, bone specimens with different bone density were sawed at different feed rates (20, 40, and 60 mm/min) and spindle speeds (9800, 11,200 and 12,600 cycles per minute). The sawing forces were recorded with a piezoelectric dynamometer and a signal acquisition system. Linear correlation analysis of all experimental data indicates that there were significant positive linear correlations between bone-sawing force and bone density and tool feed rate and a moderate negative linear correlation with tool spindle rate. By performing multiple regression analysis, the prediction models for the bone-sawing procedure were determined. By employing Omega.6 as a haptic device, a medical simulator for the Lefort I osteotomy was developed based on an experimental force model. Comparison of the force-time curve acquired through experiments and the curve computed from the simulator indicate that the obtained forces based on the experimental force model and the acquired data had the same trend for the bone-sawing procedure of orthognathic surgery.

Effect of operating parameters on the removal of bone cement by a sawing process

The number of total knee arthroplasty revision surgeries is increasing each year, driven by the wide availability and general acceptance of the procedure accompanied by an aging population of implants. Metal implants are often secured to the tibial plateau by a mantle of poly(methyl methacrylate) bone cement. During revision surgery, a power oscillating saw is used to remove bone cement while preparing the boney bed. Presently, there are no published studies on the mechanics of bone cement removal by a sawing process. The aim of this research was to quantify the effect of blade speed and applied thrust force on the volumetric cutting rate of bone cement. A custom reciprocating saw with variable stroke length was used to conduct a three-factor design of experiments. Two levels, without center-points, were sufficient to model the effect of stroke length (6.75, 10.13 mm), thrust force (11, 19 N), and reciprocating speed in strokes per minute (6000, 8000 SPM) on cutting rate. The results indicate that each of the three parameters had a significant impact on cutting rate (p < 0.001), with a linear relationship between both force and cutting rate (r = 0.98) and blade speed and cutting rate (r = 0.98). For the parameters considered, increasing the reciprocating speed had the most significant effect on cutting rate. For example, while holding force and stroke length constant (11 N, 10.13 mm), an increase in speed from 6000 to 8000 SPM nearly doubled the cutting rate of bone cement. A cutting rate model was developed by regression analysis of the experimental data and validated through additional experiments. The model has applications in haptic feedback for surgical simulators to differentiate between the cutting rates of bone and bone cement during virtual training of resident surgeons.