Surface roughness is an important parameter that determines the post-manufacturing product quality. In this study, effect of cutting parameters, coating material and the built-up edge phenomenon on the surface roughness were investigated in micro end milling process of Inconel 718 using a white light interferometer and scanning electron microscopy. A micro end mill with a diameter of 768 µm coated with five separate coating materials (AlTiN, AlCrN, TiAlN + AlCrN, TiAlN + WC/C and diamond-like carbon) was used in this study. According to the results obtained, mean surface roughness values of surfaces machined with a diamond-like carbon-coated and AlTiN-coated cutting tool were lower than for other coatings. However, surface roughness values of surfaces obtained with tools coated with TiAlN + AlCrN and AlCrN were higher. Specifically, the formation of built-up edge causes chips to be smeared on machined surfaces, which has a negative impact on the surface quality. As can be expected, wear occurs faster on uncoated tools. As a result of this, the edge radius may increase excessively, and the mean surface roughness value may decrease. Also in this study, multivariate analysis of variance was carried out and the parameter that was most effective on surface roughness was established.
In this study, the bone screwing process carried out with M3.5 cortex screw for stabilization after reduction of femur shaft fracture was investigated both experimentally and numerically. The numerical analyses were performed based on the finite element method using Deform-3D software. The friction, material model, the loading and boundary conditions were exactly identified for finite element analyses. An analytic model and software were developed, which calculate the process parameters such as screwing power and thrust power, heat transfer coefficients in order to determine the temperature distributions occurring in the screw and bone material (sawbones) during screwing process. As a result, the screwing moment and thrust force values decrease with increase of spindle speed. On the contrary, temperature values of screw and sawbones increase with increase of spindle speed. A good consistency between the results obtained from both experimental and numerical simulations was found during the bone screwing process.
Stress that occurs in syndesmotic screws is closely related to their geometry and dimensions. According to the results, a 3.5-mm cortical screw with the ideal screw design regarding optimal parameters to resist against stresses in the syndesmosis seems more reasonable to choose in syndesmotic fixation.
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