A PROJECT REPORT ON

EXPERIMENTAL AND NUMERICAL STUDY OF

EFFECT OF DRILL GEOMETRY AND SPEED ON
HEAT GENERATED DURING ORTHOPEDIC
SURGERY

Submitted in partial fulfilment of the requirements for the

award of the degree of

BACHELOR OF TECHNOLOGY
In

MECHANICAL (PRODUCTION)) ENGINEERING

Submitted by

AKASH BEN AJAY:

AJAY 14 402 005
ATHEENA TERESA PAULSON:
PAULSON 14 402 016
BHARATH H S: 14 402 019

DEPARTMENT OF MECHANICAL ENGINEERING

SREE CHITRA THIRUNAL COLLEGE OF ENGINEERING
THIRUVANANTHAPURAM 695 018
APRIL 2018
 SREE CHITRA THIRUNAL COLLEGE OF ENGINEERING
ENGINEERING,
THIRUVANANTHAPURAM
HIRUVANANTHAPURAM 695 018.
018
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the project work entitled “EXPERIMENTAL

EXPERIMENTAL AND NUMERICAL STUDY
OF EFFECT OF DRILL GEOMETRY AND SPEED ON HEAT GENERATED
DURING ORTHOPEDIC SURGERY” SURGERY is a bonafide fide work carried out in the eighth
semester by “AKASH BEN AJAY (14 402 005),, ATHEENA TERESA PAULSON
(14 402 016),, BHARATH HS (14 ( 402 019)” in partial fulfilment for the award of Bachelor
of Technology in “MECHANICAL (PRODUCTION) ENGINEERING” from University
of Kerala during the academic year 2014-2018, whoo carried out the project work under the
guidance and no part of this work has been submitted earlier for the award of any degree.

SEMINAR CO-ORDINATOR
ORDINATOR INT
INTERNAL GUIDE

Dr. E. JAYAKUMAR SHAJAN S.

Assistant professor Assistant professor
Department of Mechanical Engg. Department of Mechanical Engg.
SCT College of Engineering, SCT College of Engineering,
Thiruvananthapuram-18 Thiruvananthapuram
Thiruvananthapuram-18

HEAD OF THE DEPARTMENT CO- INT

TERNAL GUIDE

Dr. AJITH R. CHITHRA RA KUMAR V.K.

Professor Ass
Assistant Professor
Department of Mechanical Engg. Department of Mechanical Engg.
SCT College of Engineering, SCT College of Engineering,
Thiruvananthapuram-18 Thiruvananthapuram
Thiruvananthapuram-18
 ACKNOWLEDGEMENT

We take this opportunity to express our deep sense of gratitude to all those
concerned for their valuable suggestions and guidance, especially our project
guides Asst. Prof. Shajan S, Asst. Prof. Chithra Kumar V.K, Department of
Mechanical Engineering. The technical information imparted by them is
gratefully acknowledged.

We also use this opportunity to express our heartfelt thanks to

Asst. Prof. Jayakumar E and Prof. Dr. Ajith R (HOD) for facilitating us such
a wonderful opportunity to improve our learning, data collecting and
presentation skills. The encouragement and support provided by them is also
acknowledged with a lot of thanks.

We would also like to extend our thanks to our friends and family throughout
the course of this project.

Last but not the least, we would like to Thank God, the almighty, without him
this project would have been impossible.

Akash Ben Ajay

Atheena Teresa Paulson
Bharath H S

ii
 ABSTRACT

Bone fracture is common in day to day life. Fracture occurs when the bone is
subjected to the forces (direct blows, falls or twisting) which are unable to
sustain. Fractured bones are capable of healing itself naturally by generating
new bone forming cells and blood vessels at the fracture site. Therefore
restoring of the fractured parts to their initial position and maintaining them
there until the bone heals is crucial. Drilling of bone is a common procedure to
produce hole for screw insertion to fixate the fracture devices and implants for
immobilization. The magnitudes of the friction energy are greatly dependent
with the drill geometry design and the penetration angle. For the sake of
importance on studying this phenomenon, this paper aims to investigate the
effects of drill geometry on temperatures rise and hole surface in bone drilling
procedure.

This project is based on the in vitro study on the heat generated during
Orthopedic drilling by using Bovine bone, which is used as an alternative to the
human bone, due to its similar properties. The study is performed using HSS
Parallel Shank Twist drill bits on a radial drilling machine.

iii
 CONTENTS

ACKNOWLEDGEMENT ii

ABSTRACT iii

LIST OF TABLES vi

LIST OF FIGURES vii

TITLE PAGE NO:

1. INTRODUCTION 1

2. LITERATURE STUDY 2

3. PROBLEM IDENTIFICATION 10

4. OBJECTIVES 11

5. METHODOLOGY 12

6. EXPERIMENTAL STUDY 13

6.1 MATERIAL SELECTION 13

6.1.1 BONE 13

6.1.2 RADIAL DRILLING MACHINE 14

6.1.3 DRILL BIT SELECTION 15

6.1.4 DATA ACQUISITION SYSTEM (DAS) 16

6.1.5 THERMOCOUPLE 17

6.2 EXPERIMENTAL PROCEDURE 19

7. EXPERIMENTAL ANALYSIS 21

8. NUMERICAL STUDY 26

8.1 ABOUT THE SOFTWARE 26

8.2 CONDITIONS APPLIED 27

8.3 SIMULATING DRILLING PROCESSES WITH DEFORM-3D 29

iv
9. NUMERICAL ANALYSIS 30

10. DISCUSSIONS 33

11. CONCLUSION 34

12. SCOPE OF FUTURE WORKS 35

13. APPENDICES 36

14. REFERENCES 46

v
 LIST OF TABLES

Table 1: Effects of drill-bit design geometry parameters with temperature

and hole surface for different drilling penetration angle
conditions. 3

Table 2: Bovine Bone- Material Properties 14

Table 3: Drill Bit Specifications 15

Table 4: Temperature readings at 65RPM (in ˚C) 21

Table 5: Temperature readings at 119RPM (in ˚C) 21

Table 6: Temperature readings at 184RPM (in ˚C) 22

Table 7: Numerical Result 30

vi
 LIST OF FIGURES

Fig1. Basic Orthopedic Drilling Setup 4

Fig2. Broken Drill bit during orthopedic surgery 7

Fig3. The Bone specimen 13

Fig.4 Radial Drilling Machine 15

Fig.5 Drill Bits Used 16

Fig.6 Data Acquisition System (DAS) 17

Fig.7 K type thermocouple 18

Fig.8 Thermocouple fixed in Bone 19

Fig.9 Drilling Set-up 20

Fig.10 Temperature vs Drill Diameter for 65 rpm 23

Fig.11 Temperature vs Drill Diameter for 119 rpm 23

Fig.12 Temperature vs Drill Diameter for 184 rpm 24

Fig.13 Effect of Drill Speed on Bone Drilling Temperature 25

Fig.14 DEFORM-3D System Interface 27

Fig.15 Flow Stress Curve for cortical bone 28

Fig.16 Flow Stress curve inserted in DEFORM-3D 28

Fig.17 Drilling Simulation in DEFORM-3D 31

Fig.18 Temperature v/s Time graph of the drilling simulation 31

vii
 1. INTRODUCTION

Bone fracture is common in day to day life. Fracture occurs when the bone is
subjected to the forces (direct blows, falls or twisting) which are unable to
sustain. Fractured bones are capable of healing itself naturally by generating
new bone forming cells and blood vessels at the fracture site. Therefore
restoring of the fractured parts to their initial position and maintaining them
there until the bone heals is crucial. Drilling of bone is a common procedure to
produce hole for screw insertion to fixate the fracture devices and implants for
immobilization.

Orthopaedic drilling during surgical process causes increase in the bone

temperature which can result in the permanent or temporary loss of blood
supply to the bones. In the absence of blood supply, the bone tissue dies and
causes the bone to collapse, termed as thermal osteo necrosis. Therefore it is
important to minimize the thermal invasion of bone during drilling.Ideally, the
generated drilling temperature must be below °C in order to avoid thermal
necrosis. The magnitudes of the drilling temperature are greatly dependant with
the drill geometry design and should bemethodically analyse for controlling the
temperature rise.

This project is based on the in vitro study on the heat generated during
Orthopedic drilling by using PUF (Polyurethane Foam). PUF is used as an
alternative to bone, for its similar properties. The study is performed using
specially designed stainless steel surgical drill bits on a CNC drilling machine.

1
 2. LITERATURE STUDY

EFFECTS OF DRILL GEOMETRY AND PENETRATION ANGLE ON

TEMPERATURE AND HOLES SURFACES FOR CORTICAL BOVINE
BONE: AN IN VITRO STUDY. PROCEDIA ENGINEERING, 184, 70-77

NOORAZIZI, M. S., IZAMSHAH, R., & KASIM, M. S. (2017).

Based on the journal collected, it was seen that the experiments were performed
using CNC 5-Axis Machine with a drilling speed of 1000 rpm and 100 mm/min
feed rate were employed to represent the actual manual surgical hand drill speed
and surgeon penetration feed. The drilling temperatures were measured using
portable thermal infrared camera.

In this experiment, AISI 420B stainless steel medical grade rod with diameter
4.3 mm were ground to form thedrill bits with varying angles namely point
angle, helix angle and web thickness as depicted in Table 1. Stainlesssteel drill
bit exhibits good corrosion resistance and can minimize the tool wear effect.
Totals of 51 holes weredrilled with 3 holes replication for each run. To
eliminate the apparatus wear impact on the result, the apparatuswere cleaned
with a brush and wet tissue before each drilling process.

Theory predicts that a splitpoint drill would reduce friction, and that a quick
helix is neededto clear the bone debris efficiently. This would also beimproved
by the use of a parabolic flute. Such a drill bitwould be more efficient, generate
minimal friction, andreduce the production of thermal energy.

2
 Table 1: Effects of drill-bit
bit design geometry parameters with temperature and hole surface
for different drilling penetration angle conditions.

The interaction
ction between the design geometryparameter and the drilling
penetration angle significantly affect the temperature magnitudes and hole
surface. Fromthe conducted investigation, the most significant parameter that
affects the temperature rise and holes surf
surface quality
were penetration angle followed by the point angle. In addition, helix angle and
web thickness give less significanteffect on the hole performance. To conclude,
the results from the conducted experiments provide the referencevalues for the
development
lopment of high performance surgical drill design in orthopedic bone
surgeries application.

During the bone drilling process, the produced chips impact the wall of the
holes generating small cracks on thechip surface and causing them to break
when the critical
ical strain is reached. In addition, due to the deviated angle atthe
beginning of contact point causing a deformation around the hole surface. The
combination from both frictionand thermal effects increase the microfracturing
effect as the penetration angle
angl increase.
3
 OPTIMIZATION OF ORTHOPAEDIC DRILLING: A
TAGUCHI APPROACH

RUPESH KUMAR PANDEY & S.S.PANDA

Bone drilling is a common procedure to prepare an implant site during

orthopaedic surgery. An increase in temperature during such a procedure can
result in thermal ostenecrosis which may delay healing or reduce the stability of
the fixation. Therefore it is important to minimize the thermal invasion of bone
during drilling.

Fig 1: Basic Orthopedic Drilling Setup

Drilling of bone is a common procedure to produce hole for screw insertion to

fixate the fracture devices and implants for immobilization. Orthopaedic drilling
during surgical process causes increase in the bone temperature which can result
in the permanent or temporary loss of blood supply to the bones. In the absence
of blood supply, the bone tissue dies and causes the bone to collapse, termed as

4
thermal osteonecrosis. Hence, drilling of bone with minimum temperature is a
major challenge for orthopaedic fracture treatment.

In this study, effects of drill diameter, feed rate and spindle speed on
temperature generated in the dry drilling of PMMA were investigated

The maximum value of temperature obtained for each trial is used for the
analysis. This criteria was used to avoid any possibility of thermal osteonecrosis
(ON). All the values of bone temperature, not their mean values must be below
the cut-off point for ON.

5
 DRILLING OF BONE: PRACTICALITY, LIMITATIONSAND
COMPLICATIONS ASSOCIATED
WITH SURGICAL DRILL-BITS

NICKY BERTOLLO AND WILLIAM ROBERT WALSH

The drilling of bone is ubiquitous in many fields of surgery including

orthopaedics,neurosurgery, plastics and reconstructive, craniomaxillafacial and
ear nose and throat(ENT). A cylindrical tunnel is typically prepared in bone
using a surgical drill-bit toaccommodate a screw or other threaded device for
rigid fixation which is provided by theintegration of bone (cancellous and/or
cortical) with the screw threads. In thisconfiguration bone screws are resistant to
axial and shear forces as well as bendingmoments and therefore suited to the
load-bearing function of the skeleton duringlocomotion. Drill-bits are also used
in the preparation of bony tunnels, such as in anteriorcruciate ligament
reconstruction.
Drilling is associated with the conversion of mechanical work energy into
thermal energycausing a transient rise in temperature of adjacent bone and soft
tissues to above normalphysiological levels Primary sources of this thermal
energy are plastic deformation and shear failure of bone andfriction at the
machining face. The magnitude of this temperature rise is determined by a
number of factors, including drill geometry and diameter, rotational speed
(rpm), feed-rate(mm.s-1), axial thrust force (N), initial drill-bit temperature and
internal or external cooling.The negative effect of elevated temperature on the
viability of bone is well-acknowledgedand measures to reduce them during
surgery are frequently employed, such as manualirrigation with sterile saline

6
Excessive temperatures and durations at these elevated levels can result in the
necrosis(death) of bone, a phenomenon termed osteonecrosis, or the impairment
of osteogenicPotential. There is no definitive consensus regarding critical values
or their durations an increase in temperature of the cortical bone to above 50˚C
has been implicated with a reduced regenerative capacity and above 56˚C with
osteonecrosis a temperature elevation to above 47˚C which is sustained for one
minute has a potent osteo-necrotic effect. Both in vitro and in vivo
animalmodels have hitherto played a pivotal role in the determination of these
thresholdtemperatures and critical durations.
The operational environment for a surgical drill-bit is unique and very unlike
thatexperienced by engineering drill-bits used in manufacturing, or traditional
non-biologicalengineering Skiving is particularly problematic in the case of
Bi-cortical drilling of long bones as the tip can skive along the endo-steal
surface of the farDrilling of Bonecortex, which induces a bending moment on
the fluted portion of the drill-bit If of sufficient magnitude this bending moment
can increase the risk ofbreakage, with the broken portion sometimes becoming
lodged in the medullary canal.

Fig 2: Broken Drill bit during orthopedic surgery

7
The surgical drilling of bone is associated with the generation of heat which
causes atransient rise in temperature of hard and soft tissues to above normal
physiological levels.
Depending on the magnitude of the maximal temperature attained and the
duration forwhich the elevated temperature is maintained thermonecrosis of
bone may ensue. Bone isparticularly susceptible to high temperatures as it has a
relatively low thermal conductivity,the implication being that heat is not easily
dissipated.The general consensus is that a temperature of 47˚C is the
criticalthreshold limit for thermonecrosis to occur in compact bone. This can
have severe and direimplications for implant fixation as a result of osteo elastic
resorption of necrotic bone.

8
 ORTHOPAEDIC BONE DRILLS – CAN THEY BEIMPROVED?
TEMPERATURE CHANGES NEAR THE DRILLING FACE

COLIN NATALI, PAUL INGLE, JOHN DOWELL

Many orthopaedic operations involve drilling and tappingbefore the insertion of

screws into bone. It is known that anexcessive rise in temperature around a drill
hole will cause thermal necrosis of bone, and it has been shown that
temperaturesof over 50°C are associated with irreversible changes in the
structure and physical properties of bone.
The physical characteristics of bone vary considerably with its state. When it is
dry, it is said to be ‘short chipping’, since the debris is generated in
small particles that are easily cleared by a drill bit. Other short chipping
materials are brass, cast iron and hard steel and the optimal helix angle for them
is small (a slow helix). Most standard orthopaedic drill bits have this type of
helix, but at operation the debris is wet and mixed with medullary fat. In this
state bone is no longer short chipping and the flutes of a slow helix drill will
clog easily. On theoretical grounds a bone drill bit should therefore have a
quick helix.
Blunt drill bits will generate higher temperatures andeven smoke, while the
increased force required for penetrationcauses poor control of the drill,
uncontrolled burstingthrough the cortex or drill breakage.
The highest local temperatures were generated with the standard orthopaedic
drill with artificially blocked flutes, and were sustained for longer. The new
Stratec orthopaedic drill created less rise in temperature, but the lowest
temperature changes were obtained with the split-point, fast helix drill (Black
and Decker ‘Bullet’ drill).

9
 3. PROBLEM IDENTIFICATION

Excessive temperatures and durations at these elevated levels can result in the
necrosis(death) of bone, a phenomenon termed osteonecrosis, or the impairment
of osteogenic potential. Necrotic bone is resorbed through osteoclastic activity
and this can have dire andcatastrophic consequences for rigidity of bone screws
and pins, ultimately resulting in thefailure of fracture repair or implant fixation.
Whilst there is no definitive consensusregarding critical values or their
durations an increase in temperature of the cortical bone toabove 50˚C has been
implicated with a reduced regenerative capacity and above 56˚C with
osteonecrosis. Both in vitro and in vivo animalmodels have hitherto played a
pivotal role in the determination of these thresholdtemperatures and critical
durations.

• Increase in temperature results in thermal osteo necrosis which may delay

healing.

• It also reduces the stability of the fixation.

• Therefore it is important to minimise thermal invasion.

10
 4. OBJECTIVES

• To minimize the heat generation during the drilling process to as low a

value as possible

• To produce holes with very good surface finish and quality

• To create an in vitro study of bone by using bovine bone as an alternative

and create a model for study and comparison

• Drilling ofbone with minimum temperature for orthopaedic fracture

treatment.

• To investigate the effects of drill geometry on temperatures rise and hole

surface in bone drillingprocedure.

• To reduce the probability of thermal necrosis during orthopaedic surgery.

11
 5. METHODOLOGY

Orthopedic drill is one of important instruments inorthopedic surgery. It is

mainly used for drilling blind holeor through-hole at drumhead, skull, dental
and common human bones. In practical orthopedic bone hole drilling,
the surgeon must apply an appropriate axial force to ensure
the hole drilling stable and smooth. However, bone drilling is
different from metal cutting. Bone, a kind of unique multiorg composite, is
composed of organics and inorganics. Itwill suffer very complicated
deformation and forces duringdrilling.

Moreover, considering severe conditions in practicalsurgery, orthopedic drill

shall be designed and manufacturedwith sharp cutting edge, adequate stiffness
and toughness, aswell as high processing precision. In particular, it shall
beexcellent heat dissipation to control drilling temperature below 47°C. This not
only will improve the drilling qualityand fixation effect of implantation
materials, but also willshorten the recovery time of patient significantly.

Temperature at the tool-bone interface is notoriouslydifficult to measure due to

the complexities associated with placement of a temperaturemeasurement
device at this precise location. Thermocouples and infrared imaging are
twomeasurement modalities used commonly in the experimental determination
of temperatureelevation in both the in vivo and in vitro settings.

Also, the temperature is determined numerically by the simulation of the

drilling process on the software, DEFORM3D v11 to verify the result.
Temperature v/s Time graphs should be plotted to analyze the conditions which
satisfies our problem.

12
 6. EXPERIMENTAL STUDY

6.1 Material selection

6.1.1 Bone
Testing materials mainly include ox bone. The humerus bone ofadult cattle was
taken for the experiment. This is because abundant researches confirmed
that ox bone has the most similar mechanical properties andthermal properties
with human bone. However, ox bone hashigher density and thicker than human
bone. Under samedrilling conditions, drilling temperature of ox bone is
higherthan that of human bone. Hence, it could meet clinicalsurgical
requirements if necrocytosis of ox bone could be avoided. The humerus bone
has a cylindrical structure and is characterised of even thickness, compact
texture and slightmechanical property changes. It is the first choice of
testingbone sample. The cortical thickness of the used bone sample ranges
between 6~9 mm.

Fig 3: The Bone specimen

13
 Bovine Bone- Material Properties

Density 1800 kg/m³

Young’s Modulus 20000 MPa

Longitudinal Elastic Modulus 26.1 GPa

Transverse Elastic Modulus 10.9 GPa

Longitudinal Tensile Strength 140 MPa

Transverse Tensile Strength 46 Mpa

Poisson’s Ratio 0.36

Table 2: Bovine Bone- Material Properties

6.1.2 Radial Drilling Machine

The experiment used Siddhapura Universal Radial Drilling Machine Model No.
SER- I &II.Main technical parameters included:

Diameter of column 165mm

Spindle Travel 220mm

No. of Spindle Speed 62 to 1980RPM

Spindle speeds of 62, 119 and 184 RPM were used to evaluate the experimental
study. Natural air cooling was applied. The most important components are the
arm, column, and the drill head. The drill head of the radial drilling machine can
be moved, adjusted in height, and rotated.The tasks that a radial drilling

14
machine can do include boring holes, countersinking, and gri
grinding off small
particles in masonry.

Fig 4: Radial Drilling Machine

6.1.3 Drill Bit Selection

Addison parallel shank twist drill bits (Jobber Series) of diameter 4, 5 and 6mm
were used in this experiment. Diameter
ter of working part, drill bit lengths are
listed in the table shown below.
below Apex angle
le and helix angle of all the selected
twist drills are 118° and 30°.

Drill Diameter 4 mm φ 5 mm φ 6 mm φ

Flute Length 43 mm 52 mm 57 mm

Overall Length 75 mm 86 mm 93 mm

3 Drill Bit Specifications

Table 3:

15
 Fig 5: Drill Bits Used

6.1.4 Data Acquisition System (DAS)

The Agilent 34970A data acquisition / data logger switch used in this
experimental study consists of a three-slot mainframe with a built-in 6 1/2 digit
digital multimeter. Each channel can be configured independently to measure
one of 11 different functions without the added cost or hassles of signal-
conditioning accessories. Choose from eight optional plug-in modules to create
a compact data logger, full-featured data acquisition system or low-cost
switching unit. On-module screw-terminal connections eliminate the need for
terminal blocks and a unique relay maintenance feature counts every closure on
every switch for easy, predictable relay maintenance. 34901A features a built-in
thermocouple reference and 20 two-wire channels.

16
 Fig 6: Data Acquisition System (DAS)

The Agilent Technologies 34970A combines precision measurement

capability with flexible signal connections for your production and
development test systems. Three module slots are built into the rear
of the instrument to accept any combination of data acquisition or
switching modules.

6.1.5 Thermocouple

Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the

most common type of thermocouple. It’s inexpensive, accurate, reliable, and has
a wide temperature range. The type K is commonly found in nuclear
applications because of its relative radiation hardness. Maximum continuous
temperature is around 1,100C.

Type K Temperature Range: Extension wire, 32 to 392F (0 to 200C)

17
The positive and negative poles of K thermocouple are connected to the 34970A
data acquisition unit which is connected to the computer. In this way,
thermo electromotive forces produced by hot and cold ends
of the thermocouple could be collected and recognized by
34970A data acquisition unit.

Fig 7: K type Thermocouple

18
 6.2 Experimental Procedure

Since it is difficult to measure temperature inside the bone hole, this

experiment used K-thermocouple connected to DAS to measure temperature at
0.5 mm deep, of the hole wall is an experimental installation of temperature
measurement plan.

The bone sample was clamped tightly by a jaw vice. A small hole was drilled
firstly on top side of the bone and the hot end of the thermocouple was inserted
into this small hole. The hot end was in full contact with the hole
bottom. Next, the thermocouple was fixed in place with a clamp. Finally,
drilling experiment was implemented at the place of 2mm away from the hot
end.

Fig 8: Thermocouple fixed in Bone

The drilling was done 3 times with each diameter: 4, 5 and 6mm drill bits we
selected, to gain better accuracy in the temperature measurement. The
temperature readings were noted down. These were repeated for 62, 119 and
184 RPM spindle speeds, totally giving 9 sets of readings.
19
Below shown is the total arrangement of the experimental study with all the
above mentioned components.

Fig 9: Drilling Set-up

20
 7. EXPERIMENTAL ANALYSIS

The readings noted by DAS for 4, 5, and 6mm drill bit diameters at different
spindle speeds are as given below:

Temperature readings at 65RPM (in ˚C)

6mm 48.9 48.3 56.2

5mm 50.1 48.1 47.8

4mm 47.9 46.5 43.2

Table 4: Temperature readings at 65RPM (in ˚C)

Temperature readings at 119RPM (in ˚C)

6mm 44.7 49.9 48.2

5mm 41.5 45.3 44.9

4mm 42.5 41.8 42.7

Table 5: Temperature readings at 119RPM (in ˚C)

21
Temperature readings at 184RPM (in ˚C)

6mm 44.5 48.2 44.3

5mm 41 40.1 42.7

4mm 38.9 39.2 42

Table 6: Temperature readings at 184RPM (in ˚C)

7.1 The Effect of different Drill bit diameters on Bone Drilling

Temperature

Effect of drill diameter on drilling temperature was tested using same bone
sample under air cooling conditions using 4.0, 5.0, and 6.0 mm φ common twist
drill. The corresponding diameter-dependent variation curves of temperature at
the point of 5 mm deep and 2 mm away from the hole wall are shown below.

22
 Fig 10: Temperature vs Drill Diameter for 65 rpm

Fig 11: Temperature vs Drill Diameter for 119 rpm

In the plotted graphs, temperature at the measuring point shows a

linear variation trend no matter what kind of drills is used. The maximum
drilling temperature of 6mm common twist drill is 56.2°C. The maximum
drilling temperature of 5mm common twist drill is 50.1°C and that of
4mm is 47.9°C. This indicates that drilling diameter could influence drilling

23
temperature greatly. It is suggested to choose appropriate drill to lower the
drilling temperature.

Fig 12: Temperature vs Drill Diameter for 184 rpm

7.2 The Effect of Drill Speed on Bone Drilling Temperature

Influence law of speed of main shaft on drilling

temperature was analyzed by 4.0, 5.0 and 6.0 mm parallel shank twist drill bits
under air cooling conditions. Three speeds of main shaft were used: 65 r/min,
119 r/min and 184 r/min. The corresponding time-dependent variation curves of
temperature at the point 5 mm deep and 2 mm was away from the hole wall
which presented in the figures. .

It can be seen from Fig below that all three temperature curves show a linear
variation law as drilling goes on. The maximum drilling temperature of the

24
measuring point is achieved at about 15 s. The highest drilling temperatures at
same time under is 65 r/min, 119 r/min and 184 r/min are 56.2°C, 49.9°C, 4 and
48.2°C. This reflects that under same of other drilling
parameters, drilling temperature decreases with the increase of speed of main
shaft.

60
50
40
65 rpm
30
119 rpm
20
184 rpm
10
0
4 5 6

Fig 13: Effect of Drill Speed on Bone Drilling Temperature

25
 8. NUMERICAL STUDY

8.1 About the Software

For the numerical study we used Scientific Forming Technologies

Corporation (SFTC) Deform-3D v11.0. DEFORM-3D is a powerful process
simulation system designed to analyze the three-dimensional (3D) flow of
complex metal forming processes. DEFORM-3D is a practical and efficient
tool to predict the material flow in industrial forming operations without the
cost and delay of shop trials. Typical applications include: closed die forging –
open die forging – machining – rolling – extrusion – heading – drawing –
cogging – compaction – upsetting etc.

DEFORM-3D is an ‘open system’ that provides incredible flexibility to

designers and analysts working on a range of applications, development and
research. DEFORM-3D supports user routines and user defined
variables. Complex multiple deforming body capability with arbitrary contact
allows users to simulate mechanical joining and coupled die stress analysis.

Based on the finite element method, DEFORM has proven to be accurate and
robust in industrial application for more than two decades. The simulation
engine is capable of predicting large deformation material flow and thermal
behaviour with astonishing precision. DEFORM is the most widely used
simulation program in the world by leading research institutes and
manufacturers. See our product information for additional details.

26
 Fig 14: DEFORM-3D System Interface

8.2 Conditions Applied

CONDITIONS

Drill Bit 6mm φ Twist

RPM 120

Feed 0.5mm/rev

Room temperature 23˚C

Bone Density 1800 kg/m3

Young’s Modulus 20000 MPa

Longitudinal Elastic Modulus 26.1 GPa

Poisson’s Ratio 0.36

Table 7: Numerical Conditions Applied

27
Since the Material Library of DEFORM-3D didn’t have Bone as one of its
materials, the above given conditions were applied to create the Bone material
as a new entry in its library. The flow stress properties of bone were also needed
to create the new entry. Hence they were taken from the graph shown below,
and the values were plotted inside the simulator to re-create the graph and its
properties.

Fig 15: Flow Stress Curve for cortical bone

The flow stress data was taken at a constant temperature of 296K or 23˚C.

Fig 16: Flow Stress curve inserted in DEFORM-3D

28
 8.3 Simulating Drilling Processes with DEFORM-3D

Due to the number of revolutions of a drill necessary to establish characteristic

behaviour, drilling simulations in DEFORM are time consuming. Therefore,
every effort will be made to optimize problem size.

Considerations include keeping the work piece as small as possible while

capturing geometry (both in diameter and thickness), using the largest element
which can adequately capture chip geometry, and possibly pre-shaping the work
piece to eliminate the necessity to simulate the transient point penetration before
the drill reaches full depth.

29
 9. NUMERICAL ANALYSIS

The drilling simulation was carried out and the temperature v/s time graph
was plotted. The values of temperature change after each 0.1s is shown below
in ˚C:

Time (sec) Max Temperature on the Work piece(°C)

0 23

0.10126 30.03177

0.20086 31.76746

0.30046 28.32502

0.40006 34.83578

0.50132 40.67566

0.60092 42.46799

0.70052 46.98786

0.80012 50.752

0.8798 55.42126

Table 7: Numerical Result

30
The temperature v/s time graph is as shown below:

Fig 17: Drilling Simulation in DEFORM-3D

Fig 18: Temperature v/s Time graph of the drilling simulation

31
From the simulated output of a 6mm twisted drill bit running at 120RPM with a
feed of 1mm/rev, it is seen that the highest temperature calculated is 55.4˚C.
With only air cooled conditions and a feed rate not the same with the one we
done in experimental, the result still satisfies the condition. The whole process
took around only 0.87s to complete. With the help of extra coolant and slow
feed rate, the highest temperature read can be maintained and can be optimized
for our thermal necrosis dilemma.

From the numerical analysis of 6mm φ drill bit running at a speed of 120rpm,
the highest temperature recorded was 55.4°C.

While in the experimental analysis of 6mm φ drill bit at 119rpm, the highest
temperature recorded was 49.9°C

According to the results from Experimental and Numerical, there is a good

agreement between the results of both of them; however slight deviations might
have occurred due to different reasons like:

• Anisotropic behaviour

• Non uniform feed rate

• Ambient conditions

32
 10. DISCUSSIONS

Thermal insult to living tissue causes damage and eventual cell death. It
has been shown that heating above 55°C causes irreversible change to the
physical properties of bone, probably because of changes in the collagen of
the matrix. Cortical necrosis and delayed healing were reported in bovine
bone after heating to between 43.3° and 68.7°C. Our choice of 50·°C was
arbitrary, but we felt that thermal injury should be reduced to a known ‘safe’
level for local osteo blasts.

The use of a split-point drill bit, with a point angle of 118° and a quick helix
gives an improved performance, reducing the force required (and the time
for heat generation), and therefore causing less thermal damage than a
standard orthopaedic drill.

Theory suggests that further improvements may be possible; the problem of

thermal injury when drilling bone is well known to surgeons, but as yet it is
unresolved by the manufacturers of orthopaedic equipment.

33
 11. CONCLUSION

The surgical drilling of bone is associated with the generation of heat which
causes a transient rise in temperature of hard and soft tissues to above
normal physiological levels. Depending on the magnitude of the maximal
temperature attained and the duration for which the elevated temperature is
maintained thermo necrosis of bone may ensue. Bone is particularly
susceptible to high temperatures as it has a relatively low thermal
conductivity, the implication being that heat is not easily dissipated. Coupled
with a relatively low specific heat, the end result is that the inertial effect
following a localised injection of heat can be considerable. The general
consensus is that a temperature of 47˚C is the critical threshold limit for
thermo necrosis to occur in compact bone. This can have severe and dire
implications for implant fixation as a result of osteoclastic resorption of
necrotic bone. Osteogenic potential can also be compromised due to
exposure to elevated temperatures which can hinder tissue infiltration and
osteo integration required for biological fixation of implants, such as in un
cemented joint arthroplasty.

• Lowest temperature recorded was 38.9°C

• Obtained at 184 rpm, drill diameter 4mm.

• Highest temperature recorded was 56.2°C.

• Obtained at 65 rpm, drill diameter 6mm.

• Thus we conclude that temperature produced is maximum when using

low speed and large drill diameter.

• The drill shape can influence drilling temperature greatly.

34
 12. SCOPE OF FUTURE WORKS

Continual efforts are being directed at the improvement of drill-bit design to

enhance performance for the surgeon and postoperative outcome for the patient.
Ultrasonic assisted drilling is one such technology which applies ultrasonic
vibrations along the longitudinal direction of the drill-bit to assist with the
cutting process. This technology has been shown to cause reductions in both
axial thrust force and drilling torque. Feedback systems detecting real-time
cortical break-through have also been developed with the intention of
minimising the effect of break-through on hole geometry as well as minimising
the damage inflicted to soft tissues by the drill-tip.

Alternatives to the mechanical machining of bone have been developed for

dental operations, including Er: YAG lasers and piezoelectric devices.
Piezoelectric osteotomy is based on ultrasonic vibration of an osteotomic device
that permits precise cutting of bone structures without cutting adjacent soft
tissues whilst lasers cause tissue ablation. These methods have the propensity to
produce defects in an atraumatic manner which may have positive implications
for healing.

35
 13. APPENDICES

CONTENTS
EXPERIMENTAL AND NUMERICAL
STUDY OF EFFECT OF DRILL
GEOMETRY AND SPEED ON HEAT
GENERATED DURING ORTHOPEDIC
SURGERY
AKASH BEN AJAY 405
GUIDED BY: ASST. PROF. SHAJAN S. ATHEENA TERESA PAULSON 416
BHARATH HS 419

OPTIMIZATION OF ORTHOPAEDIC DRILLING: A TAGUCHI

INTRODUCTION APPROACH
RUPESH KUMAR PANDEY & S.S.PANDA
• Bone fracture is common in day to day life.

• Fracture occurs when the bone is subjected to the Diameter has the highest
influence on temperature
forces which it is unable to sustain. produced during drilling
PMMA, followed by the
• Bone drilling is a common procedure to prepare an spindle speed and feed
rate respectively.
implant site during orthopaedic surgery.

1
 ORTHOPAEDIC BONE DRILLS – CAN THEY BE
IMPROVED?
TEMPERATURE CHANGES NEAR THE DRILLING FACE
• Many orthopaedic operations involve drilling and tapping COLIN NATALI, PAUL INGLE, JOHN DOWELL
before the insertion of screws into bone.
Blunt drill bits will generate higher
temperatures and
• An excessive rise in temperature around a drill hole will cause even smoke, while the increased
thermal necrosis of bone, temperatures of over 50°C create force required for penetration and
irreversible changes in the structure and physical properties of causes poor control of the drill,
bone uncontrolled bursting through the
cortex or drill breakage

5 6

• Thermal insult to living tissue causes damage and eventual • Use of a split-point drill bit, with a point angle of 118° and a
cell death. quick helix gives an improved performance

• Heating above 50°C causes irreversible change to the

physical properties of bone , because of changes in the • Reducing the force required (and the time for heat
collagen of the matrix. generation), causes less thermal damage than a standard
orthopaedic drill.

• Cortical necrosis and delayed healing were reported in

• Increasing cortical thickness was also positively correlated
canine bone after heating to between 43.3° and 68.7°C with increasing mean maximal temperature. Cortical bone is
of a finite thickness, which has definite implications for
temperature elevation

7 8

2
 DRILLING OF BONE: PRACTICALITY, LIMITATIONS
AND COMPLICATIONS ASSOCIATED
• Many geometrical and operational variables influence both WITH SURGICAL DRILL-BITS
the performance and maximal temperature elevation in bone NICKY BERTOLLO AND WILLIAM ROBERT WALSH
as result of the use of drill-bits.
They include:
Depending on the magnitude of the
AXIAL THRUST FORCE
maximal temperature attained and the
ROTATION SPEED duration for which the elevated
TORQUE temperature is maintained thermo
SHARPNESS OF THE CUTTING EDGES necrosis of bone may ensue.
COOLING SYSTEMS (CLOSED OR OPEN LOOP)

INITIAL DRILL-BIT TEMPERATURE

CORTICAL THICKNESS

9 10

PROBLEM IDENTIFICATION OBJECTIVES

Increase in temperature results in thermal osteo To avoid thermal necrosis, temperature must be
necrosis which may delay healing. ideally below 55 deg Celsius

The variation of drilling parameters is studied to

It also reduces the stability of the fixation. achieve the optimum condition.
Therefore it is important to minimise thermal invasion.

11 12

3
EXPERIMENTAL SET UP- PHOTO EXPERIMENTAL SET UP- COMPONENTS

Bovine bone

Radial drilling
machine
4,5,6 mm φ HSS twist
drill bits
Data Acquisition
System (DAS)

Thermocouple

13 14

Bovine Bone- Material Properties

DRILL BIT SELECTION
Density 1800 kg/m³

Young’s Modulus 20000 MPa

• High Speed Steel material
Longitudinal Elastic Modulus 26.1 GPa
• Parallel shank twist drill
Transverse Elastic Modulus 10.9 GPa

Longitudinal Tensile Strength 140 MPa

Drill Diameter 4 mm φ 5 mm φ 6 mm φ
Transverse Tensile Strength 46 Mpa Flute Length 43 mm 52 mm 57 mm
Overall Length 75 mm 86 mm 93 mm

Poisson’s Ratio 0.36

15 16

4
RADIAL DRILLING MACHINE RADIAL DRILLING MACHINE
• Universal Radial Drilling Machine Model No. SER-I
& II
• Spindle Speed range - 62 to 1980RPM
• The most important components are the
arm, column, and the drill head.
• The drill head of the radial drilling machine can
be moved, adjusted in height, and rotated.
• The tasks that a radial drilling machine can do
include boring holes, countersinking, and grinding
off small particles in masonry.

17 18

THERMOCOUPLE THERMOCOUPLE

• Temperature measurement traditionally performed

by thermocouple technique.
• Sensors with dissimilar metals.
• Generate voltage when there are temperature
differences between them.

19 20

5
 DATA ACQUISITION SYSTEM (DAS)
Limitation of the thermocouple nest method :

Time involved in preparing the pilot

holes for the thermocouple probes

Inability to measure the temperature

at the tool-bone interface.

21 22

DATA ACQUISITION SYSTEM (DAS) Temperatures(°C) at 65rpm

• Collects, stores and distributes information.
6mm 48.9 48.3 56.2
• Used in industrial and commercial electronics,
and environmental and scientific equipment. 5mm 50.1 48.1 47.8

• Captures electrical signals or environmental 4mm 47.9 46.5 43.2

conditions on a computer device.
• A data acquisition system is also known as a
data logger.

23 24

6
 Temperatures(°C) at 119rpm Temperatures(°C) at 184rpm

6mm 44.7 49.9 48.2 6mm 44.5 48.2 44.3

5mm 41.5 45.3 44.9 5mm 41 40.1 42.7

4mm 42.5 41.8 42.7 4mm 38.9 39.2 42

25 26

Temperature vs Drill Diameter for 65 Temperature vs Drill Diameter for 119

rpm rpm

27 28

7
Temperature vs Drill Diameter for 184
Experimental analysis
rpm
60

50

40

65 rpm
30
119 rpm
20 184 rpm

10

0
4 5 6

29 30

NUMERICAL STUDY- DEFORM3D Drill Bit

CONDITIONS
6mm φ Twist
RPM 120
• DEFORM-3D is a powerful process simulation system
Feed 0.5mm/rev
designed to analyze the 3D flow of complex metal
forming processes. Room temperature 23˚C

• The simulation engine is capable of predicting large Bone Density 1800 kg/m3
deformation material flow and thermal behaviour
with great precision. Young’s Modulus 20000 MPa

• For the numerical study we used SFTC Deform3D Longitudinal Elastic Modulus 26.1 GPa
v11.0
Poisson’s Ratio 0.36

31 32

8
 Simulation Video Simulation Video

33 34

Numerical analysis Comparison

Time (sec) Max Temperature on the Work
piece(°C) There is a good agreement between the results of
0 23 experimental and numerical analysis, however slight
0.10126 30.03177 deviations have occured.
0.20086 31.76746
0.30046 28.32502 The following inferences were noted:
0.40006 34.83578 • Anisotropic behaviour
0.50132 40.67566
• Non uniform feed rate
0.60092 42.46799
• Ambient conditions
0.70052 46.98786
0.80012 50.752
0.8798 55.42126
35 36

9
 Result Conclusion
• From the numerical analysis of 6mm φ drill bit • Lowest temperature recorded was 38.9°C
running at a speed of 120rpm, the highest • Obtained at 184 rpm, drill diameter 4mm.
temperature recorded was 55.4°C • Highest temperature recorded was 56.2°C.
• Obtained at 65 rpm, drill diameter 6mm.
• While in the experimental analysis of 6mm φ • Thus we conclude that temperature produced
drill bit at 119rpm, the highest temperature is maximum when using low speed and large
recorded was 49.9°C drill diameter.

37 38

References References
• Noorazizi, M. S., Izamshah, R., & Kasim, M. S. (2017). Effects • Pandey, R. K., & Panda, S. S. (2012). Optimization of
of Drill Geometry and Penetration Angle on Temperature
and Holes Surfaces for Cortical Bovine Bone: An in Vitro orthopaedic drilling: a Taguchi approach. Int J Theor
Study. Procedia Engineering, 184, 70-77. Appl Res Mech Eng, 1(1), 9-12.

• Bertollo, N., & Walsh, W. R. (2011). Drilling of bone:

practicality, limitations and complications associated with
surgical drill-bits. In Biomechanics in Applications. InTech.

• Natali, C., Ingle, P., & Dowell, J. (1996). ORTHOPAEDIC BONE

DRILLS–CAN THEY BE IMPROVED?: TEMPERATURE
CHANGES NEAR THE DRILLING FACE.Bone & Joint
Journal, 78(3), 357-362.

39 40

10
 14. REFERENCES

[1] Noorazizi, M. S., Izamshah, R., & Kasim, M. S. (2017). Effects of Drill
Geometry and Penetration Angle on Temperature and Holes Surfaces for
Cortical Bovine Bone: An in Vitro Study. Procedia Engineering, 184, 70-
77.

[2] Bertollo, N., & Walsh, W. R. (2011). Drilling of bone: practicality,

limitations and complications associated with surgical drill-bits.
In Biomechanics in Applications. InTech.

[3] Natali, C., Ingle, P., & Dowell, J. (1996). ORTHOPAEDIC BONE
DRILLS–CAN THEY BE IMPROVED?: TEMPERATURE CHANGES
NEAR THE DRILLING FACE.Bone & Joint Journal, 78(3), 357-362.

[4] Pandey, R. K., & Panda, S. S. (2012). Optimization of orthopaedic

drilling: a Taguchi approach. Int J Theor Appl Res Mech Eng, 1(1), 9-12.

36
46