Optimisation of Machining Parameters for Milling Polyetheretherketones (PEEK) Biomaterial

Izamshah, R.; Long, Aaron Yu; Amran, Ali Mohd; Kasim, Mohd Shahir; Hadzley, Abu Bakar Mohd; Sivarao, Subramonian

doi:10.4028/www.scientific.net/amm.699.198

Cited by 9 publications

(8 citation statements)

References 5 publications

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“…It turned out that the cutter geometrical features had significant effects on the machined surface roughness. Abdullah et al optimized the machining parameters (cutting speed, feed rate and depth of cut) for effective machining of PEEK implant material using carbide cutting tools [6]. Based on the analysis results of Response Surface Methodology (RSM), the optimal machining parameters for the minimum surface roughness values were obtained.…”

Section: Introductionmentioning

confidence: 99%

Study of milling process basics for the biocompatible PEEK material

Cheng

Ling

et al. 2020

Mater. Res. Express

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Polyetheretherketone (PEEK) material has attracted attentions and studies in the medical field due to its excellent properties suitable for orthopedic, dental, and implant applications. In order to acquire the needed geometrical accuracy and surface finish for individual customizations of components made of PEEK material, milling process basics for PEEK material have been studied in this paper. The influences of milling parameters on milling forces and surface roughness are discussed based on single-factor and orthogonal milling experiments. It shows that the effects of cutting parameters on cutting forces are basically in accordance with that in the classical metal cutting theory. But the effects of cutting parameters on the surface roughness are different. Also the significance sequences of the key milling parameters on milling forces and surface roughness are identified. Furthermore, a finite element simulation model to estimate the milling force is established and successfully evaluated for customized applications.

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Section: Introductionmentioning

confidence: 99%

Study of milling process basics for the biocompatible PEEK material

Cheng

Ling

et al. 2020

Mater. Res. Express

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“…2D surface roughness parameters provide a simple and valuable method for quantifying contour height distribution, but they are inadequate for functional surface evaluation. Milling-induced surface topographical features are orientation-dependent that surfaces with small 2D surface roughness values do not guarantee high performance at the same time [17,18].…”

Section: Instructionmentioning

confidence: 99%

Experimental study on the cytocompatibility of milling surface of poly-ether-ether-ketone (PEEK)

Liu

Qian

2023

Int J Adv Manuf Technol

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Cytocompatibility of implant material is dependent on the processed surface topography. This study aimed to characterize the milling surface topography features and to assess the cytotoxicity of PEEK processed using end milling technology. Based on the Taguchi method, end milling experiments have been conducted on PEEK to characterize surface topographies induced by various milling conditions. Machined surface defects and 3-Dimensional surface topography parameters such as surface average height Sa, the tenpoint height of surface Sz, Skewness Ssk, and Kurtosis Sku were characterized. The relationships between the cutting technological parameters and surface topography parameters were established by developing a linear regression model. On the other hand, the effect of the machined surface topography on the viability of fibroblasts was investigated by using cells from a mouse fibroblast L929 and the agar overlay test, MTT test. The experimental result indicated that feed marks, scratch marks, budlike protuberances, the adhered surface particles are the main forms of the surface defect in the end milling of PEEK. The axial and radial depths of cut are the two most critical factors to affect surface topography parameters. Agar overlay tests produced no evidence of cell damage caused by PEEK, and a conclusion can be drawn that PEEK has no cytotoxicity to L929 cell. MTT test results indicated that milling-induced surface topography features exerted specific toxicity on L929 cells, and a statistical difference between the cell's viability of the test samples is observable. By correlation analysis, the correlations order of the viability of fibroblasts L929 with the machined surface roughness parameters were Ssk, Sa, Sku and Sz in large to small. It is concluded that end milling processing significantly affects surface topography which in turn influences the L929 fibroblast cellular response.A significant decrease of L929 viability started with the surface roughness of Sa = 1.18 μm, and surface roughness characterized by Ssk = 0.011 (namely, Ssk closed to zero) also 2 / 23 allowed to achieve the highest possible cells viability.

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“…There have been few investigations on the CPMP of such polymers, 24–27 and no one has explored the delamination phenomena. The applications of PEEK parts require good surface quality and dimensional accuracy 28 . Surface roughness values have a significant impact on the adhesion of implants to cells or tissues in the medical field 24 .…”

Section: Introductionmentioning

confidence: 99%

“…The applications of PEEK parts require good surface quality and dimensional accuracy. 28 Surface roughness values have a significant impact on the adhesion of implants to cells or tissues in the medical field. 24 Delamination issues render the surface quality and overall mechanical strength of CPMP products uncontrolled, restricting the use of PEEK CPMP technology in a variety of fields.…”

Section: Introductionmentioning

confidence: 99%

Study of the interlayer bonding strength for combined 3D printing and milling of polyetheretherketone

Zhou

Cheng

Jiang³

et al. 2023

J of Applied Polymer Sci

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Polyetheretherketone (PEEK) has good mechanical properties and biocompatibility for a wide range of biomedical applications. The combined 3D printing and milling process (CPMP) is a typical additive/subtractive hybrid manufacturing technique, which facilitates the rapid response for customized PEEK implants. This paper investigates the CPMP process combining fused deposition modeling printing and dry milling for PEEK materials. The results show that the bending and shearing effects of the milling cutter on the 3D-printed part cause the machined surface to be extremely susceptible to delamination. Poor Z-direction interlayer bonding strength at the 3D printing stage is the main cause of delamination. Therefore, the effects of 3D printing parameters (nozzle temperature, layer thickness, and bed temperature) on Z-direction interlayer bonding strength are studied using an orthogonal experiment design method. The applicability of three 3D printing infill patterns (grid, rectilinear, and gyroid) in CPMP is compared.The results of the research show that the storage modulus is a more accurate reflection of the interlayer bonding strength in the Z-direction than the shear strength. With a combination of parameters of a nozzle temperature of 450 C, a layer thickness of 0.1 mm, a bed temperature of 260 C and a rectilinear infill pattern, the 3D-printed parts have significantly stronger interlayer bonding strength.Consequently, there exists almost no delamination on the milled surface.

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Optimisation of Machining Parameters for Milling Polyetheretherketones (PEEK) Biomaterial

Cited by 9 publications

References 5 publications

Study of milling process basics for the biocompatible PEEK material

Study of milling process basics for the biocompatible PEEK material

Experimental study on the cytocompatibility of milling surface of poly-ether-ether-ketone (PEEK)

Study of the interlayer bonding strength for combined 3D printing and milling of polyetheretherketone

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