Integrated multivariate optimization of bone grinding parameters minimizing iatrogenic trauma and maximizing postoperative osteoregenerative efficacy

Bone grinding represents a technically demanding and clinically sensitive procedure integral to neurosurgical and spinal interventions, particularly in the context of lumbar disc decompression. The thermo-mechanical stresses incurred during this operation pose substantial risks to adjacent neurovascular and osseous tissues, with surface topography especially roughness playing a critical role in post-operative healing kinetics and tissue integration. This investigation employed Response Surface Methodology (RSM) via Minitab to rigorously evaluate the compounded effects of four machining parameters rotational speed, feed rate, depth of cut, and tool diameter on thermal generation, grinding force, and surface microgeometry. The thermometric analysis indicated a predominant influence of spindle speed, feed trajectory, and axial depth on temperature escalation, with the optimal thermal condition (29.40°C) achieved at 3000 rpm, 20 mm/min feed, 0.1 mm cutting depth, and 8 mm tool diameter. Grinding force exhibited multidimensional sensitivity, with a nadir of 0.54 N observed under 5000 rpm in a transverse cutting configuration relative to osteonal microarchitecture. Surface roughness was largely dictated by tool diameter, engagement depth, and anatomical cutting orientation, with an optimal Ra value of 0.57 µm attained under parallel osteonal alignment. Collectively, the results delineate a high-fidelity parametric framework for minimizing deleterious thermal loads and mechanical disruptions during bone grinding. This framework advances precision surgery protocols and promotes biomechanically favorable outcomes in osseous tissue manipulation.