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Surface morphology generation mechanism of cortical bone axial ultrasonic vibration-assisted drilling
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DOI：10.1016/j.cirpj.2026.06.003.png)
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Abstract
En 中文
Minimally invasive orthopedic surgery (MIOS) requires high-quality borehole wall morphology, because drilling quality directly affects implant stability. To address crack propagation and fragmentation pits induced by conventional drilling (CD) in heterogeneous cortical bone, this study develops a geometry-damage coupled simulation framework integrating multidimensional tool kinematics, cutting-envelope theory, stochastic damage perturbations, ultrasonic suppression effects, and bone mineral density (BMD) heterogeneity. A kinematic model of the instantaneous tool-tip trajectory with high-frequency ultrasonic perturbation was established, and the predicted morphology was validated using bovine femoral cortical-bone drilling experiments, in-situ infrared thermography, confocal laser scanning microscopy, and scanning electron microscopy. Results show that ultrasonic vibration-assisted drilling (UVAD) promotes the transition of borehole wall formation from random brittle spalling and pit-like defects to regular periodic microtextures dominated by kinematic envelopes, while improving robustness against BMD-induced damage variation. Experimental results further showed that increasing ultrasonic amplitude from 0 to 3 μm reduced the areal roughness parameter Sa by 77.3%, while UVAD reduced the measured peak near-surface temperature from 53 °C to 46 °C at 1500 rpm and 30 mm·min⁻¹ , corresponding to a 14% reduction. A critical amplitude threshold was identified, beyond which geometric forming effects prevail. The proposed model provides a predictive tool for personalized low-damage bone drilling.
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