Enhancement of Kirschner Wire for Bone Drilling

2014 ◽  
Author(s):  
Bruce L. Tai ◽  
Fumitake Nonoyama ◽  
Yancheng Wang ◽  
Albert J. Shih
Keyword(s):  
Thrust Force ◽  
Kirschner Wire ◽  
Element Model ◽  
Bone Drilling ◽  
Drilling Tool ◽  
Excessive Heat ◽  
Drilling Performance ◽  
Drill Bits ◽  
Design And Manufacturing ◽  
Maximum Thrust

This study advances design and manufacturing of the tip geometry of the Kirschner wire (K-wire) — a popular orthopedic drilling tool with a sharp, three-sided trocar point — for improved bone drilling efficiency. Since there is no active cutting edge as there is for twist drill bits, bone drilling forces can be so large as to cause excessive heat generation and tool wear. Our modified K-wire consists of three slots at the tip to enhance cutting and chip (bone debris) evacuation. A finite element model was developed to simulate bone debris generation, thus predicting the improvement by the slot design. An experimental study was conducted to validate the model and ascertain actual drilling performance. During 5 mm drilling the maximum thrust force and torque were both reduced on average by 30–40% based on the experimental data. The overall trends of both force and torque agree with the model-predicted results.

Modelling of thrust force for worn drill bits characterised by cutting edge radius in drilling carbon fibre–reinforced plastic/Ti-6Al-4V alloy stacks

2017 ◽  
Vol 232 (11) ◽  
pp. 1960-1972 ◽  
Author(s):  
Bin Luo ◽  
Kaifu Zhang ◽  
Yuan Li ◽  
Hui Cheng ◽  
Shunuan Liu
Keyword(s):  
Tool Wear ◽  
Carbon Fibre ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Edge Radius ◽  
Reinforced Plastics ◽  
Edge Radius ◽  
Drill Bits ◽  
Carbon Fibre Reinforced Plastics ◽  
Maximum Thrust

Wear rates are rapid when drilling carbon fibre–reinforced plastics/Ti-6Al-4V alloy stacks because of their distinct mechanical properties. Tool wear leads to a high thrust force, thereby reducing the quality of the drilled holes. This article develops a novel mechanistic model for carbon fibre–reinforced plastics/Ti-6Al-4V stacks, which is characterised by the cutting edge radius, to predict the variation of the thrust force when drilling with worn drill bits. Drilling experiments with varying feed rates were performed using carbide twist drill bits. The thrust force and drill edge profile were measured to calibrate and validate the presented model. The edge radius increases with both the cutting distance and number of drilled holes at varying feed rates. It was found that the growth rate of the edge radius increased with the feed rate with identical cutting distances, whereas it decreased slightly with the feed rate when the number of drilled holes was identical. Tool wear reduces the equivalent rake angle of the drill edge, resulting in higher thrust force. The maximum thrust force increases almost linearly with the edge radius of worn drills for both materials. The predicted thrust force curves are in very good agreement with the measured curves during the entire process. Average absolute errors of the maximum thrust force for carbon fibre–reinforced plastics and Ti-6Al-4V alloy are 3.24% and 1.88%, respectively.

Data Analytics and Physics-Based Simulation Enable Bit, Motor, and BHA Combination

2020 ◽  
Vol 72 (12) ◽  
pp. 53-54
Author(s):  
Chris Carpenter
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Data Analytics ◽  
Element Model ◽  
Work Flow ◽  
Drill Bit ◽  
Offshore Technology ◽  
Drilling Performance ◽  
Drill Bits ◽  
Physics Based Simulation

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper OTC 29875, “Combined Data Analytics and Physics-Based Simulation for Optimal Bit, Motor, and Bottomhole Assembly Combination,” by Samba Ba, SPE, Dmitry Belov, SPE, and Daniel Nobre, SPE, Schlumberger, et al., prepared for the 2019 Offshore Technology Conference Brasil, Rio de Janeiro, 29-31 October. The paper has not been peer reviewed. Copyright 2020 Offshore Technology Conference. Reproduced by permission. Today, drill bits and mud motor issues can account for more than half of the reasons for pulling out of hole before total depth (TD) on directional drilling wells. The complete paper presents a methodology designed for optimally matching drill bits, mud motors, and bottomhole-assembly (BHA) components for reduced failure risks and improved drilling performance. Work Flow The overall work flow includes detailed modeling of each sophisticated component and an algorithm to combine them efficiently at the system level without losing their specific nature. Drilling-Bit Simulation. The drill-bit model is created in 4D - 3D space modeling plus the transient behavior with time. In 4D finite-element modeling, both polycrystalline-diamond-compact (PDC) and reverse-circulation bits can be modeled. The detailed cutting structure model may include specifying the number of cutters and how to place them in a 3D cutter space. The bit cutter and rock interaction must be modeled correctly to simulate the real scenario. This interaction is characterized by laboratory testing for almost all types of rocks interacting with the cutters. Motor Simulation. The mud motor consists of multiple subassemblies. The power section assembly is where the transformation of hydraulic power into mechanical power occurs; this consists of a rotor/stator pair. The rotor is the moving part and the stationary stator is a metal tube with rubber bonded inside. The authors developed a motor- optimization modeling work flow for evaluating the mud motor’s performance and durability for any defined drilling conditions. This model includes performance, fatigue, and hysteresis heating simulation capabilities. Within the framework of the developed work flow, the authors use three types of simulation (mechanical, thermal, and fatigue), with mutual correlations between the results. Drillstring Simulation. A proper drill-string simulation is critical for the successful evaluation of drilling performance and equipment reliability. In this study, the drillstring and BHA analysis consists of a comprehensive full-scale finite-element model that also includes a proper transient analysis of the drilling process in a 4D analysis. This finite- element model uses 3D beam elements with six degrees of freedom for each finite-element node. The described complex finite-element model incorporates all components from drill bit to surface. This model considers factors affecting the dynamic performance of the drillstring and can predict the transient response in the time domain. Detailed working mechanisms and geometries of downhole drive tools were implemented in the model to study the dynamic characteristics and directional performance of these tools.

scholarly journals Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack

2021 ◽  
Vol 5 (7) ◽  
pp. 189
Author(s):  
Muhammad Hafiz Hassan ◽  
Jamaluddin Abdullah ◽  
Gérald Franz ◽  
Chim Yi Shen ◽  
Reza Mahmoodian
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Critical Dimension ◽  
Helix Angle ◽  
Single Shot ◽  
Twist Drill ◽  
Hole Quality ◽  
Drilling Parameters ◽  
Industry Practice ◽  
Maximum Thrust

Drilling two different materials in a layer, or stack-up, is being practiced widely in the aerospace industry to minimize critical dimension mismatch and error in the subsequent assembly process, but the compatibility of the drill to compensate the widely differing properties of composite is still a major challenge to the industry. In this paper, the effect of customized twist drill geometry and drilling parameters are being investigated based on the thrust force signature generated during the drilling of CFRP/Al7075-T6. Based on ANOVA, it is found that the maximum thrust force for both CFRP and Al7075-T6 are highly dependent on the feed rate. Through the analysis of maximum thrust force, supported by hole diameter error, hole surface roughness, and chip formation, it is found that the optimum tool parameters selection includes a helix angle of 30°, primary clearance angle of 6°, point angle of 130°, chisel edge angle of 30°, speed of 2600 rev/min and feed rate of 0.05 mm/rev. The optimum parameters obtained in this study are benchmarked against existing industry practice of the capability to produce higher hole quality and efficiency, which is set at 2600 rev/min for speed and 0.1 mm/rev for feed rate.

GPU-Based Haptic Simulator for Dental Bone Drilling

2011 ◽  
Author(s):  
Fei Zheng ◽  
WenFeng Lu ◽  
Yoke San Wong ◽  
Kelvin Weng Chiong Foong
Keyword(s):  
Real Time ◽  
Graphics Processing Units ◽  
Force Feedback ◽  
Mandibular Canal ◽  
Structure Design ◽  
Patient Specific ◽  
Force Model ◽  
Bone Drilling ◽  
The Real ◽  
Drill Bits

Dental bone drilling is an inexact and often a blind art. Dentist risks damaging the invisible tooth roots, nerves and critical dental structures like mandibular canal and maxillary sinus. This paper presents a haptics-based jawbone drilling simulator for novice surgeons. Through the real-time training of tactile sensations based on patient-specific data, improved outcomes and faster procedures can be provided. Previously developed drilling simulators usually adopt penalty-based contact force models and often consider only spherical-shaped drill bits for simplicity and computational efficiency. In contrast, our simulator is equipped with a more precise force model, adapted from the Voxmap-PointShell (VPS) method to capture the essential features of the drilling procedure. In addition, the proposed force model can accommodate various shapes of drill bits. To achieve better anatomical accuracy, our oral model has been reconstructed from Cone Beam CT, using voxel-based method. To enhance the real-time response, the parallel computing power of Graphics Processing Units is exploited through extra efforts for data structure design, algorithms parallelization, and graphic memory utilization. Preliminary results show that the developed system can produce appropriate force feedback at different tissue layers.

Surface characteristics and machining performance of TiAlN-, TiN- and AlCrN-coated tungsten carbide drills

2018 ◽  
Vol 233 (4) ◽  
pp. 1075-1086 ◽  
Author(s):  
Chaiya Dumkum ◽  
Pakin Jaritngam ◽  
Viboon Tangwarodomnukun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Average Error ◽  
Force Model ◽  
Machining Performance ◽  
Coating Materials ◽  
Drilling Performance

This article presents a comprehensive analysis of surface characteristics and drilling performance of uncoated and coated tungsten carbide drills. The single- and double-layer coatings of TiN, TiAlN and AlCrN were examined in terms of surface roughness, microhardness and crack resistance. In addition, drilling torque and thrust force were experimentally measured and compared to the developed models based on the drilling mechanics and drill geometries. Tool wear and hole surface roughness were also considered to assess the machining performance of different coated tools. The results revealed that all coated drills can offer better cut surface quality, 28% lower cutting loads and longer tool life than the uncoated drills. Although AlCrN was found to be the hardest coating material among the others, it caused large wear on the cutting edges and poor surface roughness of produced holes. The lowest torque and thrust force were achievable using TiN-coated drill, while the use of TiAlN coating resulted in the lowest surface roughness and smallest tool wear. Furthermore, the drilling torque and thrust force model developed in this study were found to correspond to the experimental measures with the average error of 8.4%. The findings of this work could facilitate the selection of coating materials to advance the machining performance.

Bit Dysfunction Characterization Using a Sensor System at the Bit

2007 ◽  
Author(s):  
Sorin G. Teodorescu ◽  
Eric C. Sullivan ◽  
Paul E. Pastusek
Keyword(s):  
Structural Integrity ◽  
Sensor System ◽  
Sensor Data ◽  
Drilling Performance ◽  
Rock Formations ◽  
Drill Bits ◽  
Pdc Bit ◽  
Recent Developments ◽  
Drilling Operations ◽  
Rock Bit

Drilling operations represent a major cost in discovering and exploring new petroleum reserves. Poor drilling performance, for example low ROP, can lead to high cost per foot. In order to optimize the performance of drill bits, the dynamic behavior of the bit and the drillstring has to be monitored. In recent developments, we have deployed a sensor / data acquisition (DAQ) system that is mounted at the bit, which can monitor the behavior of the drill bit and dynamic dysfunctions associated with the operating parameters, different rock formations and rock/bit interactions. A modified shank accommodates the sensor / DAQ system. Its location was determined based on extensive analysis of the bit’s structural integrity. Initial tests verified the ability of the system to identify PDC bit dysfunctions, such as backward whirl — one of the most bit damaging events in the drilling operation. Placing a sensor system in the bit allows for accurate pattern recognition and severity determination in terms of dynamic dysfunctions of the bit and can aid in optimizing drilling parameters in pursuit of increased ROP and reduced drilling costs.

Drilling Force and Chip Morphology in Drilling of PCB Supported Hole

2011 ◽  
Vol 188 ◽  
pp. 429-434 ◽  
Author(s):  
L.P. Yang ◽  
Li Xin Huang ◽  
Cheng Yong Wang ◽  
L.J. Zheng ◽  
Ping Ma ◽  
...  
Keyword(s):  
Feed Rate ◽  
Printed Circuit Board ◽  
Thrust Force ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Circuit Board ◽  
Drilling Process ◽  
Drilling Force ◽  
Drill Bits

Supported holes of Printed circuit board (PCB) are drilled with two different drill bits. Drilling force (thrust force and torque) and chip morphology are examined at different cutting parameters, and the effects of the two drills are discussed. The results indicate that the drilling force and chip morphology are affected by the feed rate, spindle speed and drill shape. Thrust force increases with the increasing feed rate, and decreases with the increasing spindle speed. Optimization of drill geometry can reduce the thrust force significantly, and is effective in chip breaking which can improve the chip evacuation during the drilling process.

Experimental Study on Orbital Drilling Force and Machining Quality of CFRP

2014 ◽  
Vol 1061-1062 ◽  
pp. 542-549
Author(s):  
Xue Mei Chen ◽  
Qing Liang Chen ◽  
Feng Tao He ◽  
Xi Feng Fan
Keyword(s):  
Thrust Force ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Drilling Force ◽  
Drilling Tool ◽  
Orbital Drilling ◽  
Reinforced Plastic ◽  
Predominant Factor

This paper aims to investigate orbital drilling process in carbon-fiber reinforced plastic (CFRP) composites with multi-point orbital drilling tool based on the robot automatic drilling system. One orthogonal experiment has been carried out, and the cutting forces of different parameters were measured online by dynamometer. Furthermore, the cutting force model was established through regression analysis, and the impacts of cutting parameters on thrust force were deeply analyzed. In addition, delamination and tear defects were inspected respectively, and the relationship between thrust force and delamination and tear was discussed. Our results indicate that thrust force increased with the increasing feed rate and axial feed depth, while decreased with the increasing spindle speed. Axial feed depth was found as the predominant factor on thrust force and defects. At last, the cutting parameters was optimized and then thrust force decreased more than 26% with almost none tear and burr around the hole, which indicates a better machine quality.

Automatic Bone Drilling in Orthopedic Surgery - Overcoming of the Drill Bit Bending at the Second Cortex

2014 ◽  
Vol 664 ◽  
pp. 419-422 ◽  
Author(s):  
George Boiadjiev ◽  
Kamen Delchev ◽  
Tony Boiadjiev ◽  
Kazimir Zagurski ◽  
Rumen Kastelov
Keyword(s):  
Orthopedic Surgery ◽  
Force Control ◽  
Thrust Force ◽  
Screw Fixation ◽  
Drill Bit ◽  
Bone Surface ◽  
Active Force ◽  
Bone Drilling ◽  
Bone Damage ◽  
Specific Shape

This paper discusses a problem appeared by drill bit bending during bone drilling in the orthopedic surgery, where precision is needed for screws to be implanted. The bone surface has a specific shape and the drill bit may slip a little along the bone before the process start, when a large thrust force is applied by hand-drilling. That could be seen and correct by the surgeon. But he can’t see inside – where the second cortex drilling starts. The drill bit bending leads to the worse screw fixation and even to the bone damage – if the drill bit stays off broken inside. To solve this problem an active force control is made by robot application. Experiments and results are presented.

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