Mechanistic modeling of bone-drilling process with experimental validation

•A mechanistic model is developed to predict thrust force and torque.•Only four calibration experiments are required for the model.•The model can predict drilling forces nicely in a wide range of drilling conditions.

In this paper, an improved mechanistic model is developed to predict the thrust force and torque for bone-drilling operation. The cutting action at the drill point is divided into three regions: the cutting lips, outer portion of the chisel edge (the secondary cutting edges), and inner portion of the chisel edge (the indentation zone). Models that account for the unique mechanics of the cutting process for each of the three regions are formulated. The models are calibrated to bovine cortical bone material using specific cutting pressure equations with modification to take advantage of the characteristics of the drill point geometry. The models are validated for the cutting lips, the chisel edge, and entire drill point for a wide range of spindle speed and feed rate. The predicted results agree well with experimental results. Only the predictions for the drilling torque on the chisel edge are lower than the experimental results under some drilling conditions. The model can assist in the selection of favorable drilling conditions and drill-bit geometries for bone-drilling operations.