Numerical and experimental study of orthogonal cutting bone using elastic-plastic material model and dynamic damage model

Today, bone machining is known as one of the most important steps in orthopedic surgery. With accurate and effective simulation of machining process can achieve faster patient recovery and high efficiency in surgery. Accordingly, estimating and controlling the production temperature in machining is necessary to prevent excessive heat generation and thermal damage to the bone. The study of the orthogonal cutting process is important because of the basis of other machining processes. Therefore, an experimental and numerical study was performed for orthogonal machining. An elastic-plastic model was used as the material model to predict cortical bone behavior in finite element simulation. The damage model was used for complete material failure, tool penetration and chip formation. The simulation was done for the first time with the damage model and its results were analyzed for the first time with the response surface method and sensitivity analysis using the Sobel method for each parameter separately and the interaction of the parameters. The simulation results are in agreement with the experimental results. According to the optimization, the minimum temperature is about 26ºC when the cutting depth is 0.1 mm, the cutting speed is about 192 mm/s and the rake angle is 12º. This study can be effective in further advancing the bone machining process and lead to progress in orthopedic surgery, optimization of machining parameters and tool design.