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ANCA > 5 Practical Steps to Making Rotary Instruments that Surgeons Want
to Use - Step 1
5 Practical Steps to Making Rotary Instruments that Surgeons
Want to Use - Step 1
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Step 1: Apply some fresh techniques from industrial cutting tool design
Rotary instruments used in surgical procedures have much in common with rotary tools used in industry. Bone drills need to
efficiently and safely penetrate and evacuate heterogeneous layers of material; a task thats similar in many ways to drilling
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holes in composite structures that you find in the aerospace industry. Bone drills tend to be long and skinny just like deep hole
drills used to drill injector seats in cylinder heads.
Industrial rotary tools such as drills, endmills, taps, reamers and burs are consumed in the millions every day. This volume has
led to huge investments in refining their design and manufacturing techniques so they now cut better and stay sharp much
longer. It makes sense to learn what we can from industrial tool design and transfer the relevant insights to medical instrument
projects.
So today, well start with an overview of industrial drill design and in the next installment, well go into detail about how bone
drills differ from their industrial cousins.
The geometry of a traditional conical point drill is shown below:
Point Angle
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The point angle balances lateral stability and thrust requirements against tool strength and edge
sharpness. A steeper point angle produces a sharper tip which requires less axial force on the
drill to make it penetrate and consequently, makes the drill less prone to wander off center.
But the tradeoff is that the sharper tip will blunt quicker, is more prone to chipping and has a
higher tendency to grab; particularly on through penetration or from one layer to another.
Lip
The lip is another important feature of the drill point. Traditional conical point drills are designed
with a straight lip section from the chisel edge to the margin. The lip shape is formed by the
intersection of the lip relief surface and the flute surface, so the flute shape is critical. Modern
drills are designed using very specialized 3D CAD systems that can produce straight lips,
purposely curved lips or anything in-between.
They do this by generating custom shaped grinding wheels or flute cutters. These systems even
work for steeper point angle helical drills (common for bone drills) where its difficult to make a lip
shape that cuts efficiently right to the margin instead of rubbing and generating excess heat and
the potential for bone necrosis.
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Kennametal HP KSEM5
By the way, these images were produced from actual 3D models designed using one of those specialized CAD systems we
mentioned earlier.
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Facet relieved drill point with 1) primary and 2) secondary reliefs and 3) a gash walk
Helix
Probably the biggest lesson to learn from industrial drilling is that helically fluted tools work much
better than shear tools. Many long drills, such as gun drills used to be made with long, straight or
slightly sheared flutes with the cutting point ground onto the tip. These tips cut OK, but getting
the chips out of the hole was a big problem. And long shear tools lack the natural 360 degree
supporting characteristics of helical tools; even those with small margins.
So it was common to design shear drills with large margins, which also added to heat build-up.
Recent advances in software (that well look at in part 2) and manufacturing techniques (part 3)
have now made it possible to accurately make long skinny high performance drills with helical
flutes and thin margins. Just like an auger, the helical drill naturally draws chips out of the hole.
You should always consider a helical fluted design over a shear design whenever possible.
Today, we gave you a quick overview of some features that are important in modern industrial drills. In the next installment of
this 5 part eCourse, well go into detail about how bone drills differ from their industrial cousins and why.
>> Step 1: Apply some fresh techniques from industrial cutting tool design
Step 2: Optimize instrument geometry to match the specifics of bone structure
Step 3: Leverage the advantages of grinding over Swiss turning
Step 4: Select a material and grinding wheel to suit your bone drill
Step 5: Drill your way deep into the medical components market
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