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.