This study addresses a challenges in the thermomechanical modeling of cortical bone machining, including the lack of fully coupled temperature–mechanical models, limited use of temperature-dependent constitutive laws, and insufficient integration of orthogonal and oblique cutting mechanisms within a unified framework. A comprehensive numerical approach is proposed to model drilling and planing of a cortical bone. A 3D finite element (FE) drilling model, inherently involving oblique cutting mechanics, is first developed to capture realistic thermomechanical interactions during surgical bone drilling. Subsequently, simplified 3D planing models (orthogonal and oblique cutting) are introduced to isolate fundamental cutting mechanisms and validate temperature predictions under controlled conditions, concerning the diversified tool-workpiece interactions induced by the tool geometry (e.g. helix angle). The model incorporates a temperature-dependent term in the Johnson–Cook (JC) constitutive law, improving the prediction of material behavior under coupled thermal and mechanical loads. Simulations are conducted to analyze the influence of feed rate and drilling speed on cutting forces and temperature evolution. Results demonstrate that these parameters significantly affect heat generation, with higher values leading to pronounced temperature increases and variations in material response. The proposed model enables obtainment of prediction errors below 11% for thrust force and generally below 5% for a temperature.The findings provide guidelines for optimizing feed rate and drilling speed, based on maximization of the total desirability function, to minimize thermal damage, reduce machining loads, and enhance process efficiency. These results are particularly relevant for orthopedic applications, where controlling temperature is critical to preventing thermal necrosis and improving surgical outcomes.
Rajouh et al. (Sat,) studied this question.