Finite element modelling of low-speed femur reaming using reamers with irregular tooth spacing

Reaming of the cancellous bone of the femur is performed in certain orthopaedic procedures, in order to accommodate insertion of implants such as intramedullary nails. In such processes, the reamers spin at a maximum of 250 rev/min resulting in low-frequency vibrations, which can result in the formation of multicornered holes or non-cylindrical holes. These non-cylindrical holes can lead to improper fixation, which increases healing duration. Simulation of low-speed reaming in the femur analogue was conducted by using a finite element model of the reamer with two different models for reamer blade loads: concentrated forces on the tool tip and distributed forces on the engagement length of the reamer. The model of the process is quasi-static in a characteristic form. The specific cutting pressure, an important parameter in the governing equation, was found experimentally for this purpose. The effects of reaming condition, reamer size, and irregular tooth spacing on stability were investigated. An optimum irregular tooth spacing for a common six-flute reamer, resulting in the most stable reaming process was proposed. Hole profiles and tool axis trajectory of the tool were simulated for both regular and optimum irregular tooth spacing cases. The improvements in the hole quality from using the proposed irregular tooth spacing; benefits of which include expedition of post-operative healing, were demonstrated through simulated three-dimensional hole profiles.