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<p>Many biomedical implants, such as knee, shoulder, and hip joints, require high compressive strength, excellent biocompatibility, and corrosion resistance over time, and are thus made of CoCrMo alloy. However, the high compressive strength, corrosion resistance, toughness, wear resistance, and low thermal conductivity of CoCrMo make it challenging to machine effectively. Additionally, the high density of CoCrMo alloy results in heavier and more expensive implants. To address these issues, this paper explores an approach to reduce the weight and cost of implants by manufacturing CoCrMo alloy samples with 40% and 50% porosity through a cold compaction with space holder powder metallurgical process. The machining of biomedical implants, particularly those with 3D sculptured surfaces, is difficult due to the alloy’s 19% machinability. In this research attempt, CoCrMo alloy foam with 40% and 50% porosity is manufactured and then machined using ball mill to optimize the machining parameters affecting the process. A total of nine sets of sculptured surface machining experiments were conducted on each porosity level using an Okuma CNC milling machine with a Kistler 9257B force measurement dynamometer. The minimum force observed with 50% porosity level was 182.968 N at a spindle speed of 1592 rpm, with a tool feed of 0.03 mm/rev and a rate of feed 192 mm/min. While, for 40% porosity level the minimum force was 263.474 N at spindle speed of 1592 rpm, feed 0.03 mm/rev and rate of feed 192 mm/min. The simulation of the milling procedure demonstrated a strong correlation with the experimental findings. The simulated environment thus created can be utilized to predict the machining parameters required with other material properties and porosity levels. The porous structure of the implants made by this technique also facilitates bone growth within the implant itself, highlighting an additional advantage of this research.</p>

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Computational and Experimental Analysis of Sculptured Surface Machining of Porous CoCrMo Medical Grade Alloy Made with Cold Compaction PM Route

  • 期刊论文

  • 发表日期：

    2025年7月11日

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  • Bahadur Singh Rajput,
  • Sharad Kumar Pradhan,
  • Alka Bani Agrawal

摘要

Many biomedical implants, such as knee, shoulder, and hip joints, require high compressive strength, excellent biocompatibility, and corrosion resistance over time, and are thus made of CoCrMo alloy. However, the high compressive strength, corrosion resistance, toughness, wear resistance, and low thermal conductivity of CoCrMo make it challenging to machine effectively. Additionally, the high density of CoCrMo alloy results in heavier and more expensive implants. To address these issues, this paper explores an approach to reduce the weight and cost of implants by manufacturing CoCrMo alloy samples with 40% and 50% porosity through a cold compaction with space holder powder metallurgical process. The machining of biomedical implants, particularly those with 3D sculptured surfaces, is difficult due to the alloy’s 19% machinability. In this research attempt, CoCrMo alloy foam with 40% and 50% porosity is manufactured and then machined using ball mill to optimize the machining parameters affecting the process. A total of nine sets of sculptured surface machining experiments were conducted on each porosity level using an Okuma CNC milling machine with a Kistler 9257B force measurement dynamometer. The minimum force observed with 50% porosity level was 182.968 N at a spindle speed of 1592 rpm, with a tool feed of 0.03 mm/rev and a rate of feed 192 mm/min. While, for 40% porosity level the minimum force was 263.474 N at spindle speed of 1592 rpm, feed 0.03 mm/rev and rate of feed 192 mm/min. The simulation of the milling procedure demonstrated a strong correlation with the experimental findings. The simulated environment thus created can be utilized to predict the machining parameters required with other material properties and porosity levels. The porous structure of the implants made by this technique also facilitates bone growth within the implant itself, highlighting an additional advantage of this research.