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Optimization of Surgical Drill Margin Dimension to Reduce Bone Temperature

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Abstract:

Excessive heat generation during bone drilling is a leading cause of thermal osteonecrosis—a serious risk in medical departments. Despite extensive drill design research, the influence of margin geometry remains underexplored. This study presents finite element modeling and statistical optimization to evaluate and optimize drill margin geometry—specifically margin width (Mw) and height (Mh)—to reduce bone temperature rise during surgery. A thermo-mechanical finite element model was developed in DEFORM-3D to simulate cortical bone drilling using drill bits with varied margin dimensions. The models were validated experimentally using bovine cortical bone, with an average temperature prediction errors of 2.4–8.0%. The maximum bone temperature (Tmax) was selected as the objective function. A central composite design (CCD) was applied to generate experimental runs, followed by response surface methodology (RSM) and desirability-based optimization. The second-order effect of Mw contributed 47.2% to Tmax. The optimal Mh (0.05 mm) and Mw (0.22 mm)—with a desirability value of 0.985—could reduce Tmax below the osteonecrosis level with only a 44.8 °C temperature rise. This study demonstrates a novel computational approach for optimizing surgical drill margins—a previously underutilized parameter. The findings may support future developments in drill bit customization and robotic surgery systems to minimize thermal injury to bone cells.

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Periodical:

Key Engineering Materials (Volume 1053)

Pages:

27-37

DOI:

https://doi.org/10.4028/p-tq4LRt

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Online since:

May 2026

Authors:

Mohd Faizal Ali Akhbar*, Shahrizan Jamaludin, Rodianah Alias

Keywords:

Bone Drilling, Drill Margin, Osteonecrosis, Temperature, Thermal Necrosis

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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