Design, Analysis and Manufacturing of a Bone Cutting Ultrasonic Horn-Tool and Verification with Experimental Tests

Horn is one of the main components of ultrasonic cutting systems. The most important characteristics of the horn design are its resonant frequency and amplification factor. Closed-form equations can be used only for the design of simple horns and do not apply to more complex shapes like surgical tools. In This paper, a designing technique based on the finite element method and experimental tests is presented. The conventional design methods are improved, and designing a high performance surgical ultrasonic horn for bone cutting tools is facilitated. The new and complex bone cutting tool has both the knife-edge and toothed-edge, which could cut the bone easily and accurately. The investigations of cutting forces applied to the tool edges show less force in the toothed edge than the knife edge.