Abstract
The aim of this paper is to conduct an experimental study in order to obtain a roughness (Ra) prediction model for dry end-milling (with an AlTiCrSiN PVD-coated tool) of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni biomedical alloys, a model that can contribute to more quickly obtaining the desired surface quality and shortening the manufacturing process time. An experimental plan based on the central composite design method was adopted to determine the influence of the axial depth of cut, feed per tooth and cutting speed process parameters (input variables) on the Ra surface roughness (response variable) which was recorded after machining for both alloys. To develop the prediction models, statistical techniques were used first and three prediction equations were obtained for each alloy, the best results being achieved using response surface methodology. However, for obtaining a higher accuracy of prediction, ANN models were developed with the help of an application made in LabView for roughness (Ra) prediction. The primary results of this research consist of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni prediction models and the developed application. The modeling results show that the ANN model can predict the surface roughness with high accuracy for the considered Co–Cr alloys.
Highlights
The most commonly used materials for manufacturing medical implants are stainless steels, titanium alloys and CoCrMo alloys [1,2,3,4].Co–Cr based alloys were patented in 1913, being initially used for applications requiring outstanding resilience in high-temperature corrosion and the first alloys of this class were called Stellites [4,5,6]
The materials that are the subject of this research study are two Co–Cr based alloys used in medical applications: a CoCrMo alloy (Co–28Cr–6Mo) with a high content of Chromium used in the medical practice for manufacturing implants for dentistry and orthopedic applications, and a CoCrWNi (Co–20Cr–15W–10Ni) alloy used in the medical practice for manufacturing joint replacements, as hip and knee implants [1,10,16]
For the Co–20Cr–15W–10Ni alloy, the Ra seems to exceed 2 μm starting with data set 29 for 2 of artificial neural network (ANN)
Summary
Co–Cr based alloys were patented in 1913, being initially used for applications requiring outstanding resilience in high-temperature corrosion (aircraft engines) and the first alloys of this class were called Stellites [4,5,6]. From the six classes of Cobalt alloys standardized in ISO 5832, four are specific to the orthopedic domain. These alloys are available both as cast and wrought products. The Co–Cr alloys recommended for use in medical applications can be classified in the following alloying systems: CoCrMo alloy, CoCrWNi alloy, CoNiCrMo alloy and CoNiCrMoWFe alloy [9,10,11]
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