Three-dimensional finite element model of the drilling process used for fixation of Salter–Harris type-3 fractures by using a K-wire

Abstract. In this study, the drilling process was performed with Kirschner wire (K-wire) for stabilization after reduction of Salter–Harris (SH) type-3 epiphyseal fractures of distal femur. The study was investigated both experimentally and numerically. The numerical analyses were performed with finite element method (FEM), using DEFORM-3D software. Some conditions such as friction, material model and load and boundary must be identified exactly while using FEM. At the same time, an analytic model and software were developed, which calculate the process parameters such as drilling power and thrust power, heat transfer coefficients and friction coefficient between tool–chip interface in order to identify the temperature distributions occurring in the K-wire and bone model (Keklikoǧlu Plastik San.) material during the drilling process. Experimental results and analysis results have been found as consistent with each other. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 80° N, 120° N, 69 °C and 61 °C for 400 rpm in experimental studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 65° N, 87° N, 91 °C and 82 °C for 800 rpm in experimental studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 85° N, 127° N, 72 °C and 67 °C for 400 rpm in analysis studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 69° N, 98° N, 83 °C and 76 °C for 800 rpm in analysis studies. A good consistency was obtained between experimental results and finite element analysis (FEA) results. This proved the validity of the software and finite element model. Thus, this model can be used reliably in such drilling processes.