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<p>Bone machining procedures are essential in orthopedic and dental surgeries because they require an ideal surface quality to facilitate implant attachment and promote post-surgical recovery. The current experimental research involves a systematic assessment of tool material (SS316L and ZrO<sub>2</sub>) inserts and multiple machining strategies on the topography of synthetic cortical bone samples. A 3-axis and a 5-axis CNC machine were used for experiments, with feed rates between 0.02 and 0.05&#xa0;mm per tooth, speed ranges of 900–1100&#xa0;rpm, and test cases with only one pass and several passes. Contact and non-contact profilometry were used to gauge the roughness parameters of <i>Ra and Rz</i>. Moderate feed (0.03&#xa0;mm/tooth) and high spindle speed (1000&#xa0;rpm) yielded the best results for the SS316L inserts, with average <i>Ra</i> and <i>Rz</i> values of 12.6 and 73.7&#xa0;µm, respectively. This was attributed to the better heat transfer (16.3 W/m·K) of the SS316L inserts. Meanwhile, tools made from ZrO<sub>2</sub> showed higher stability, lower roughness (Ra ~ 16&#xa0;µm, Rz ~ 91&#xa0;µm), and better performance at higher feed (0.05&#xa0;mm/tooth) and multiple passes, owing to their sturdiness and resistance to wear, despite their low thermal conductivity (2.5 W/m·K). At 1100&#xa0;rpm on the spindle, ZrO<sub>2</sub> maintained an even surface, but SS316L began to become rougher and unstable. The results reveal that selecting the appropriate combination of tool materials and machining settings helps maintain the bone’s strength around the implant. SS316L is used for precise, gentle cuts, but milling with resistive ZrO<sub>2</sub> is better for intense, stable milling that wears less.</p>

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Quantitative Evaluation of Bone Surface Integrity in Multi-pass Machining Using Sustainable ZrO2 Milling Inserts

  • 期刊论文

  • 发表日期：

    2026年4月2日

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  • Phanindra Addepalli,
  • Worapong Sawangsri,
  • Saiful Anwar Che Ghani,
  • Waris Darumas,
  • Jirratha Pansoonthorn,
  • Benyapa Thongchai

摘要

Bone machining procedures are essential in orthopedic and dental surgeries because they require an ideal surface quality to facilitate implant attachment and promote post-surgical recovery. The current experimental research involves a systematic assessment of tool material (SS316L and ZrO2) inserts and multiple machining strategies on the topography of synthetic cortical bone samples. A 3-axis and a 5-axis CNC machine were used for experiments, with feed rates between 0.02 and 0.05 mm per tooth, speed ranges of 900–1100 rpm, and test cases with only one pass and several passes. Contact and non-contact profilometry were used to gauge the roughness parameters of Ra and Rz. Moderate feed (0.03 mm/tooth) and high spindle speed (1000 rpm) yielded the best results for the SS316L inserts, with average Ra and Rz values of 12.6 and 73.7 µm, respectively. This was attributed to the better heat transfer (16.3 W/m·K) of the SS316L inserts. Meanwhile, tools made from ZrO2 showed higher stability, lower roughness (Ra ~ 16 µm, Rz ~ 91 µm), and better performance at higher feed (0.05 mm/tooth) and multiple passes, owing to their sturdiness and resistance to wear, despite their low thermal conductivity (2.5 W/m·K). At 1100 rpm on the spindle, ZrO2 maintained an even surface, but SS316L began to become rougher and unstable. The results reveal that selecting the appropriate combination of tool materials and machining settings helps maintain the bone’s strength around the implant. SS316L is used for precise, gentle cuts, but milling with resistive ZrO2 is better for intense, stable milling that wears less.