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<p>Thermal injury during bone drilling remains a serious problem in orthopaedic, dental, and maxillofacial surgery, especially when dry or limited irrigation techniques are used. In this study, the thermal response of SS316L and zirconia (ZrO₂) drill bits during dry drilling of synthetic bone was systematically investigated by conducting a complete 3 × 3 × 3 full-factorial experimental design. Three feed rates (30, 40, and 50&#xa0;mm/min), spindle speeds (900, 1100, and 1300&#xa0;rpm), and drill diameters (2.5, 3.0, and 3.5&#xa0;mm) were evaluated. The following thermal parameters were evaluated: Maximum temperature (<i>T</i><sub><i>max</i></sub>), Mean temperature (<i>T</i><sub><i>mean</i></sub>), corrected temperature rise (<i>T*</i><sub><i>max</i></sub>), material-dependent temperature difference (ΔTmax), Peak-to-mean ratio (PMR). 47&#xa0;°C was chosen as the critical threshold for osteonecrosis. The results indicated that the ZrO₂ drill bits were able to offer better thermal control than SS316L in most drilling conditions. The <i>T</i><sub><i>max</i></sub> of ZrO₂ was maintained at approximately 30.5–46.0&#xa0;°C and stayed below the critical temperature in all of the tested conditions, while SS316L was raised to 61.0&#xa0;°C and exceeded the safety temperature under several low feed rate and moderate to high feed rate conditions. The thermal benefit of zirconia was found to be strong, with a maximum temperature difference of 28.75&#xa0;°C between SS316L and ZrO₂. The corrected temperature rise and PMR values were also lower in ZrO₂, with generally lower values of 1.10–1.20, representing lower thermal spikes. The chip evacuation and shorter contact time during higher feed rate, particularly 50&#xa0;mm/min, caused less heat generation. In general, ZrO₂ exhibits low thermal conductivity, high hardness, and thermal stability, which are promising properties for replacing conventional stainless-steel drills in safe dry bone-drilling applications.</p>

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A full-factorial experimental design of an exhaustive thermal response of zirconia drill bits during dry bone drilling

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Phanindra Addepalli,
  • Worapong Sawangsri,
  • Pakanun Wattanasinbumrung,
  • Saiful Anwar Che Ghani,
  • Chaiyakorn Thitiyanaporn

摘要

Thermal injury during bone drilling remains a serious problem in orthopaedic, dental, and maxillofacial surgery, especially when dry or limited irrigation techniques are used. In this study, the thermal response of SS316L and zirconia (ZrO₂) drill bits during dry drilling of synthetic bone was systematically investigated by conducting a complete 3 × 3 × 3 full-factorial experimental design. Three feed rates (30, 40, and 50 mm/min), spindle speeds (900, 1100, and 1300 rpm), and drill diameters (2.5, 3.0, and 3.5 mm) were evaluated. The following thermal parameters were evaluated: Maximum temperature (Tmax), Mean temperature (Tmean), corrected temperature rise (T*max), material-dependent temperature difference (ΔTmax), Peak-to-mean ratio (PMR). 47 °C was chosen as the critical threshold for osteonecrosis. The results indicated that the ZrO₂ drill bits were able to offer better thermal control than SS316L in most drilling conditions. The Tmax of ZrO₂ was maintained at approximately 30.5–46.0 °C and stayed below the critical temperature in all of the tested conditions, while SS316L was raised to 61.0 °C and exceeded the safety temperature under several low feed rate and moderate to high feed rate conditions. The thermal benefit of zirconia was found to be strong, with a maximum temperature difference of 28.75 °C between SS316L and ZrO₂. The corrected temperature rise and PMR values were also lower in ZrO₂, with generally lower values of 1.10–1.20, representing lower thermal spikes. The chip evacuation and shorter contact time during higher feed rate, particularly 50 mm/min, caused less heat generation. In general, ZrO₂ exhibits low thermal conductivity, high hardness, and thermal stability, which are promising properties for replacing conventional stainless-steel drills in safe dry bone-drilling applications.