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A reliable clean process for five-axis milling of knee prostheses

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Abstract

Prosthesis production for hips, knees, and other human body elements, including dental implants and spine screws, requires eliminating any risk of material damage or contamination. Five-axis milling is the most suitable technique to manufacture tailor-made prostheses for different personalized sizes with affordable costs. Human life expectancy is growing, so the demand of a higher prosthesis lifecycle and manufacturing optimization is a current necessity. In this work, a robust five-axis milling process using cryogenic CO2 as coolant fluid is presented and applied to a Ti6Al4V knee implant. Ti6Al4V (grade 5 and grade 23) alloys are very difficult to cut without lubri-cooling using oil emulsion coolant; however, this emulsion implies risks from introducing little oil drops entrapped in surface roughness valleys, hampering the cleaning process before patient’s surgery. CO2 reduces this risk uncertainty, making machining operations more feasible and suitable regarding environmental sustainability. In terms of feasibility, the surface finishing, roughness, and residual stresses was analysed, obtaining a standard of IT4-IT5, N4 and compressive stresses, respectively. Virtual simulation of machining is also a key in five-axis to make a more robust industrial process.

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Acknowledgements

The authors would also like to thank the vice-rector of innovation, social commitment, and cultural action of the UPV/EHU (Bizialab programme of the Basque Government), the UPV/EHU itself for the financial aid for the pre-doctoral grants PIF 19/161, also to MACROPISTAS (PID2019-104488RB-I00) of the Spanish Ministry of Economy and Competitiveness and ELKARTEK program, from the Department of the Basque Government related to the project with the acronym COPTER.

Data and materials availability

Not applicable. No data relating to people or animals have been recorded during this work.

Funding

The authors wish to thank the University of the Basque Country for the support that enabled this study to be carried out.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, University of the Basque Country (UPV/EHU), Ingenieros Torres Quevedo Plaza, 1, 48013, Bilbao, Spain

    Gaizka Gómez-Escudero, Aner Jimeno Beitia, Gonzalo Martínez de Pissón Caruncho & Haizea González-Barrio

  2. Aeronautics Advanced Manufacturing Center (CFAA), University of the Basque Country (UPV/EHU), Parque Tecnológico de Bizkaia-Ed.202, 480170, Zamudio, Spain

    Luis Norberto López de Lacalle & Octavio Pereira Neto

  3. Department of Mechanical Engineering, University of the Basque Country (UPV/EHU), Nieves Cano 12, 01006, Vitoria-Gastéiz, Spain

    Amaia Calleja-Ochoa

Authors
  1. Gaizka Gómez-Escudero
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  2. Aner Jimeno Beitia
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  3. Gonzalo Martínez de Pissón Caruncho
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  4. Luis Norberto López de Lacalle
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  5. Haizea González-Barrio
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  6. Octavio Pereira Neto
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  7. Amaia Calleja-Ochoa
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Contributions

“Conceptualization, A.C. and N.L.; methodology, H.G.; software, G.M.; validation, A.J., O.P. and G.G.; writing—review and editing, H.G.; project administration, N.L.; funding acquisition, N.L. All authors have read and agreed to the published version of the manuscript.”

Corresponding author

Correspondence to Haizea González-Barrio.

Ethics declarations

Ethics approval and consent to participate

Not applicable. Since this study has not worked with either humans or animals. Not applicable. This paper develops the process of manufacturing a knee prosthesis. Since this prosthesis has not been transplanted to any person, no consent for publication has been required from any person.

Consent for publication

Not applicable. It has not been necessary to ask for the consent of any person, since the work has been focused on the manufacture of a knee prosthesis, and not on the process of implantation in a person.

Conflict of interest

“The authors declare no conflict of interest.” “The funders had no role in the design of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript, or in the decision to publish the results”.

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Highlights

- CO2 showed good results as coolant in Ti6al4V and reduces a source of oil contamination.

- Reductions in time would be derived from virtual engineering and simulation.

- Reduction in time and a sound production process is the only way to manufacture adapted or Taylor-made prostheses in short times.

- The full process is explained, giving clues for further works.

- Few works about knee prostheses manufacturing are, at least less than hip ones.

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Gómez-Escudero, G., Jimeno Beitia, A., Martínez de Pissón Caruncho, G. et al. A reliable clean process for five-axis milling of knee prostheses. Int J Adv Manuf Technol 115, 1605–1620 (2021). https://doi.org/10.1007/s00170-021-07220-1

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  • DOI: https://doi.org/10.1007/s00170-021-07220-1

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