Mechanistic Model to Predict Forces in Bone End Milling: An Experimental Study Intended for Bone Grafting Surgery

Area of Science:

• Biomaterials Engineering
• Orthopedic Surgery
• Manufacturing Processes

Background:

• Subtractive manufacturing, including milling, is crucial in orthopedic surgery for procedures like implant placement and reconstruction.
• Uncontrolled forces during bone cutting can lead to mechanical damage, such as micro-cracks and fragmentation, compromising surgical outcomes.
• Harvesting bone grafts using milling requires precise force control to preserve graft integrity and host bone quality.

Purpose of the Study:

• To investigate the end milling process for bone graft harvesting.
• To develop and validate a mechanistic model for predicting bone end milling forces.
• To enable pre-estimation of cutting forces to prevent mechanical damage to bone.

Main Methods:

• Developed an analytical description of milling forces, incorporating cutter geometry and bone properties.
• Calculated cutting and edge force coefficients.
• Predicted axial, tangential, and radial force components using the mechanistic model.
• Validated the model's predictions through experimental testing.

Main Results:

• The mechanistic model accurately predicted axial, tangential, and radial forces during bone end milling.
• Experimental validation confirmed the model's predictions aligned well with measured forces.
• The developed model provides a reliable method for estimating forces in bone milling.

Conclusions:

• The mechanistic model successfully predicts bone end milling forces.
• Accurate force prediction allows for the avoidance of mechanical damage to bone during graft harvesting and other orthopedic procedures.
• This research contributes to safer and more effective orthopedic surgeries utilizing subtractive manufacturing techniques.