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<p>Longitudinal-torsional ultrasonic vibration milling (LTUVM) of cortical bone was investigated to address cracking and surface damage during milling. Comparative experiments were conducted between LTUVM and conventional milling (CM). Single-factor and response surface experiments were employed to analyze the effects of cutting parameters on milling forces. Scanning electron microscopy (SEM) and three-dimensional (3D) surface morphology observations were used to investigate crack propagation mechanisms and surface quality differences. Tribological compatibility was evaluated through dry friction and simulated body fluid (SBF) wear tests. Results indicated that LTUVM reduced the combined milling force by 28.9–32.9%, shortened crack lengths by 58–67%, and significantly improved surface roughness compared to CM, compared with conventional milling, the reduction rates of surface roughness Sa in the corresponding directions for longitudinal-torsional composite ultrasonic vibration-assisted milling reach 40.1%, 38.7%, and 33.1% respectively. Response surface optimization identified optimal parameters: parallel cutting direction, spindle speed of 4100–4200&#xa0;rpm, feed rate of 50–55&#xa0;mm/min, cutting depth of 0.5–0.6&#xa0;mm, and vibration amplitude of 4.5–4.7&#xa0;μm. Wear tests showed that LTUVM-processed cortical bone exhibited a wear rate reduction of 42–53% in SBF, with superior lubrication film retention and biocompatibility. It was demonstrated for the first time that LTUVM processing significantly enhances the tribological performance of the bone–implant interface under simulated physiological conditions. These findings suggest that the novel LTUVM approach can achieve lower-damage bone machining and provide a theoretical basis for the development of ultrasonic-assisted orthopedic surgical instruments.</p>

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Study on the effects of longitudinal-torsional ultrasonic vibration on cortical bone milling performance

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Hao Niu,
  • Wenyuan Dong,
  • Fuxia Zhang,
  • Hongzhao Li,
  • Chunyu Zhang,
  • Lei Wang,
  • Weifeng Zhang

摘要

Longitudinal-torsional ultrasonic vibration milling (LTUVM) of cortical bone was investigated to address cracking and surface damage during milling. Comparative experiments were conducted between LTUVM and conventional milling (CM). Single-factor and response surface experiments were employed to analyze the effects of cutting parameters on milling forces. Scanning electron microscopy (SEM) and three-dimensional (3D) surface morphology observations were used to investigate crack propagation mechanisms and surface quality differences. Tribological compatibility was evaluated through dry friction and simulated body fluid (SBF) wear tests. Results indicated that LTUVM reduced the combined milling force by 28.9–32.9%, shortened crack lengths by 58–67%, and significantly improved surface roughness compared to CM, compared with conventional milling, the reduction rates of surface roughness Sa in the corresponding directions for longitudinal-torsional composite ultrasonic vibration-assisted milling reach 40.1%, 38.7%, and 33.1% respectively. Response surface optimization identified optimal parameters: parallel cutting direction, spindle speed of 4100–4200 rpm, feed rate of 50–55 mm/min, cutting depth of 0.5–0.6 mm, and vibration amplitude of 4.5–4.7 μm. Wear tests showed that LTUVM-processed cortical bone exhibited a wear rate reduction of 42–53% in SBF, with superior lubrication film retention and biocompatibility. It was demonstrated for the first time that LTUVM processing significantly enhances the tribological performance of the bone–implant interface under simulated physiological conditions. These findings suggest that the novel LTUVM approach can achieve lower-damage bone machining and provide a theoretical basis for the development of ultrasonic-assisted orthopedic surgical instruments.