Effect of operating parameters on the removal of bone cement by a sawing process.

The number of total knee arthroplasty revision surgeries is increasing each year, driven by the wide availability and general acceptance of the procedure accompanied by an aging population of implants. Metal implants are often secured to the tibial plateau by a mantle of poly(methyl methacrylate) bone cement. During revision surgery, a power oscillating saw is used to remove bone cement while preparing the boney bed. Presently, there are no published studies on the mechanics of bone cement removal by a sawing process. The aim of this research was to quantify the effect of blade speed and applied thrust force on the volumetric cutting rate of bone cement. A custom reciprocating saw with variable stroke length was used to conduct a three-factor design of experiments. Two levels, without center-points, were sufficient to model the effect of stroke length (6.75, 10.13 mm), thrust force (11, 19 N), and reciprocating speed in strokes per minute (6000, 8000 SPM) on cutting rate. The results indicate that each of the three parameters had a significant impact on cutting rate (p < 0.001), with a linear relationship between both force and cutting rate (r = 0.98) and blade speed and cutting rate (r = 0.98). For the parameters considered, increasing the reciprocating speed had the most significant effect on cutting rate. For example, while holding force and stroke length constant (11 N, 10.13 mm), an increase in speed from 6000 to 8000 SPM nearly doubled the cutting rate of bone cement. A cutting rate model was developed by regression analysis of the experimental data and validated through additional experiments. The model has applications in haptic feedback for surgical simulators to differentiate between the cutting rates of bone and bone cement during virtual training of resident surgeons.

Effect of applied force and blade speed on histopathology of bone during resection by sagittal saw.

A sagittal saw is commonly used for resection of bone during joint replacement surgery. During sawing, heat is generated that can lead to an increase in temperature at the resected surface. The aim of this study was to determine the effect of applied thrust force and blade speed on generating heat. The effect of these factors and their interactions on cutting temperature and bone health were investigated with a full factorial Design of Experiments approach for two levels of thrust force, 15 N and 30 N, and for two levels of blade oscillation rate, 12,000 and 18,000 cycles per minute (cpm). In addition, a preliminary study was conducted to eliminate blade wear as a confounding factor. A custom sawing fixture was used to crosscut samples of fresh bovine cortical bone while temperature in the bone was measured by thermocouple (n=40), followed by measurements of the depth of thermal necrosis by histopathological analysis (n=200). An analysis of variance was used to determine the significance of the factor effects on necrotic depth as evidenced by empty lacunae. Both thrust force and blade speed demonstrated a statistically significant effect on the depth of osteonecrosis (p<0.05), while the interaction of thrust force with blade speed was not significant (p=0.22). The minimum necrotic depth observed was 0.50mm, corresponding to a higher level of force and blade speed (30 N, 18,000 cpm). Under these conditions, a maximum temperature of 93°C was measured at 0.3mm from the kerf. With a decrease in both thrust force and blade speed (15N, 12,000 cpm), the temperature in the bone increased to 109°C, corresponding to a nearly 50% increase in depth of the necrotic zone to 0.74 mm. A predictive equation for necrotic depth in terms of thrust force and blade speed was determined through regression analysis and validated by experiment. The histology results imply that an increase in applied thrust force is more effective in reducing the depth of thermal damage to surrounding bone than an increase in blade speed.