Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Study of surface roughness, texture, and dimensional accuracy in thread whirling of Ti6Al4V screw

Document Type : Original Article

Authors
Amir Rasti 1
Mohammad Tarshizi 2
Ali Zeinolabedin-Beygi 3
1 Assistant Professor, Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
2 MSc Graduate, Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
3 PhD Student, Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
10.22034/ijme.2024.460623.1966
Abstract
The production of orthopedic screws of Ti6Al4V alloy presents challenges due to the need for a fast, cost-effective method of cutting difficult-to-cut alloys. This study addresses these issues by determining the kinematics of thread whirling for orthopedic screws made of Ti6Al4V alloy and investigating the effect of cutting parameters on the dimensional accuracy and texture of spinal screws. The proposed method enables rapid production while maintaining high precision. The main process parameters, such as tool rotational speed and workpiece feed rate, were varied at two levels for a total of four samples. The output parameters included surface roughness, thread root surface texture, sidewall profile, and thread angle. The results showed that a higher feed rate produced a rougher thread root surface and a lower ploughing effect. This increased roughness was considered ideal because it promotes cell growth on the screw surface and improves screw osteointegration in bone tissue. Furthermore, increasing the cutting speed, while creating a serrated texture on the thread wall, improved overall screw quality by reducing cutting force and eliminating crown thread defects. Within the specified manufacturing tolerance, the effect of cutting parameters on thread angle was negligible.
Keywords
Thread Whirling
Pedicle Screw
Ti6Al4V
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