Kirchhoff's law-based velocity-controlled motion models to predict real-time cutting forces in minimally invasive surgeries.

A theoretical framework, united by a "system effect" is formulated to model the cutting/haptic force evolution at the cutting edge of a surgical cutting instrument during its penetration into soft biological tissue in minimally invasive surgery. Other cutting process responses, including tissue fracture force, friction force, and damping, are predicted by the model as well. The model is based on a velocity-controlled formulation of the corresponding equations of motion, derived for a surgical cutting instrument and tissue based on Kirchhoff's fundamental energy conservation law. It provides nearly zero residues (absolute errors) in the equations of motion balances. In addition, concurrent closing relationships for the fracture force, friction coefficient, friction force, process damping, strain rate function (a constitutive tissue model), and their implementation within the proposed theoretical framework are established. The advantage of the method is its ability to make precise real-time predictions of the aperiodic fluctuating evolutions of the cutting forces and the other process responses. It allows for the robust modeling of the interactions between a medical instrument and a nonlinear viscoelastic tissue under any physically feasible working conditions. The cutting process model was partially qualitatively verified through numerical simulations and by comparing the computed cutting forces with experimentally measured values during robotic uniaxial biopsy needle constant velocity insertion into artificial gel tissue, obtained from previous experimental research. The comparison has shown a qualitatively similar adequate trend in the evolution of the experimentally measured and numerically predicted cutting forces during insertion of the needle.

Pore formation driven by particle impact in laser powder-blown directed energy deposition.

Process defects currently limit the use of metal additive manufacturing (AM) components in industries due to shorter fatigue life, potential for catastrophic failure, and lower strength. Conditions under which these defects form, and their mechanisms, are starting to be analyzed to improve reliability and structural integrity of these highly customized parts. We use in situ, high-speed X-ray imaging in conjunction with a high throughput laser, powder-blown directed energy deposition setup to observe powder particle impact behavior within the melt pool. Through fundamental observations of the stochastic, violent powder delivery in powder-blown DED, we uncover a unique pore formation mechanism. We find that a pore can form due to air-cushioning, where vapor from the carrier gas or environment is entrapped between the solid powder particle surface and liquid melt pool surface. A critical time constant is established for the mechanism, and X-ray computed tomography is used to further analyze and categorize the new type of "air-cushioning" pores. It is shown that the air-cushioning mechanism can occur under multiple laser processing conditions, and we show that air-cushioning pores are more likely to be formed when powder particles are larger than 70 µm. By quantifying the effect of powder particle impact, we identify new avenues for development of high-quality laser, powder-blown DED products. Furthermore, we deepen knowledge on defect formation in metal additive manufacturing, which is being increasingly utilized in high performance situations such as aerospace, automotive, and biomedical industries.

High-throughput, in situ imaging of multi-layer powder-blown directed energy deposition with angled nozzle.

Laser metal additive manufacturing has become an increasingly popular technology due to its flexibility in geometry and materials. As one of the commercialized additive processes, powder-blown directed energy deposition (DED) has been used in multiple industries, such as aerospace, automotive, and medical device. However, a lack of fundamental understanding remains for this process, and many opportunities for alloy development and implementation can be identified. A high-throughput, in situ DED system capable of multi-layer builds that can address these issues is presented here. Implications of layer heights and energy density are investigated through an extensive process parameter sweep, showcasing the power of a high-throughput setup while also discussing multi-layer interactions.

A high-fidelity simulation of double-sided incremental forming: Improving the accuracy by incorporating the effects of machine compliance.

Double-Sided Incremental Forming (DSIF) is a technology for the rapid, flexible manufacturing of sheet metal parts. DSIF is highly nonlinear, requiring the use of complex finite element (FE) models to optimize and control the process in order to meet geometric accuracy and sheet thinning design criteria. Current FE models do not properly take into account the effects of machine compliance, which reduces their accuracy and hinders their use for optimization and control. The aim of this work is to create a greatly improved FE model of DSIF by taking a novel approach of modeling the aggregate effects of machine and tool compliance. The accuracy of the new model was extensively validated using the local geometry, thickness distribution, principal strains, and forming forces from a funnel experiment. The validated model was used to accurately predict the spatial distribution and time-histories of the equivalent plastic strain, von Mises equivalent stress, stress triaxiality, and Lode angle parameter across and along the sheet metal. The stress state was found to rapidly change through the sheet thickness, from highly compressive between the tools and the sheet, to a mixture of generalized shear and plane strain elsewhere. Moreover, the compressive regions between the two DSIF tools created a constrained deformation zone, which likely aids in prolonging the onset of excessive thinning. This improved FE model can now be used to quantitatively characterize the nonlinear local deformation mechanisms inherent to the DSIF process, thereby providing a solid foundation for future advances in process control.

Manipulation and Localized Deposition of Particle Groups with Modulated Electric Fields.

This paper presents a new micro additive manufacturing process and initial characterization of its capabilities. The process uses modulated electric fields to manipulate and deposit particles from colloidal solution in a contactless way and is named electrophoretically-guided micro additive manufacturing (EPµAM). The inherent flexibility and reconfigurability of the EPµAM process stems from electrode array as an actuator use, which avoids common issues of controlling particle deposition with templates or masks (e.g., fixed template geometry, post-process removal of masks, and unstable particle trapping). The EPµAM hardware testbed is presented alongside with implemented control methodology and developed process characterization workflow. Additionally, a streamlined two-dimensional (2D) finite element model (FEM) of the EPµAM process is used to compute electric field distribution generated by the electrode array and to predict the final deposition location of particles. Simple particle manipulation experiments indicate proof-of-principle capabilities of the process. Experiments where particle concentration and electric current strength were varied demonstrate the stability of the process. Advanced manipulation experiments demonstrate interelectrode deposition and particle group shaping capabilities where high, length-to-width, aspect ratio deposits were obtained. The experimental and FEM results were compared and analyzed; observed process limitations are discussed and followed by a comprehensive list of possible future steps.

In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing.

Powder-blown laser additive manufacturing adds flexibility, in terms of locally varying powder materials, to the ability of building components with complex geometry. Although the process is promising, porosity is common in a built component, hence decreasing fatigue life and mechanical strength. The understanding of the physical phenomena during the interaction of a laser beam and powder-blown deposition is limited and requires in-situ monitoring to capture the influences of process parameters on powder flow, absorptivity of laser energy into the substrate, melt pool dynamics and porosity formation. This study introduces a piezo-driven powder deposition system that allows for imaging of individual powder particles that flow into a scanning melt pool. Here, in-situ high-speed X-ray imaging of the powder-blown additive manufacturing process of Ti-6Al-4V powder particles is the first of its kind and reveals how laser-matter interaction influences powder flow and porosity formation.

Design and models of helical needle geometries for core biopsies.

Biopsy needles are standard medical devices for extracting biological tissue with the purpose of diagnosing a specific anomaly such as cancerous masses, or lumps. The outcome of these procedures greatly relies on the quality of the samples which, in turn, depends on the forces acting on the needle during its insertion. In this scenario, the design of the needle tip plays a fundamental role in determining the cutting forces. Yet, since the dawn of modern medicine, only a few studies have proposed novel needle tip configurations. In this study, the geometry of biopsy needles is investigated, and helical cutting edges characterized by a three-dimensional (3D) profile are conceived. Mathematical models were formulated to compute the cutting angles and the tissue fracture forces. The proposed methodology is general and can be applied to any 3D needle cutting edge geometry. The utility of the helical geometry was demonstrated on a 14-gauge hollow needle which is generally used during breast biopsies. Experimental insertions were performed at different cutting speeds on phantom tissue. The results show that helical needles generate lower cutting forces than commercial needles and recommendations are formulated for the selection of their cutting parameters. The outcome of this investigation is applicable to biopsy examinations in which a hollow needle is adopted to acquire soft tissue samples.

Quantifying Discretization Errors in Electrophoretically-Guided Micro Additive Manufacturing.

This paper presents process models for a new micro additive manufacturing process termed Electrophoretically-guided Micro Additive Manufacturing (EPµAM). In EPµAM, a planar microelectrode array generates the electric potential distributions which cause colloidal particles to agglomerate and deposit in desired regions. The discrete microelectrode array nature and the used pulse width modulation (PWM) technique for microelectrode actuation create unavoidable process errors-space and time discretization errors-that distort particle trajectories. To combat this, we developed finite element method (FEM) models to study trajectory deviations due to these errors. Mean square displacement (MSD) analysis of the computed particle trajectories is used to compare these deviations for several electrode geometries. The two top-performing electrode geometries evaluated by MSD were additionally investigated through separate case studies via geometry variation and MSD recomputation. Furthermore, separate time-discretization error simulations are also studied where electrode actuating waveforms were simulated. The mechanical impulse of the electromechanical force, generated from these waveforms is used as the basis for comparison. The obtained results show a moderate MSDs variability and significant differences in the computed mechanical impulses for the actuating waveforms. The observed limitations of the developed process model and of the error comparison technique are briefly discussed and future steps are recommended.

Study on design and cutting parameters of rotating needles for core biopsy.

Core needle biopsies are widely adopted medical procedures that consist in the removal of biological tissue to better identify a lesion or an abnormality observed through a physical exam or a radiology scan. These procedures can provide significantly more information than most medical tests and they are usually performed on bone lesions, breast masses, lymph nodes and the prostate. The quality of the samples mainly depends on the forces exerted by the needle during the cutting process. The reduction of these forces is critical to extract high-quality tissue samples. The most critical factors that affect the cutting forces are the geometry of the needle tip and its motion while it is penetrating the tissue. However, optimal needle tip configurations and cutting parameters are not well established for rotating insertions. In this paper, the geometry and cutting forces of hollow needles are investigated. The fundamental goal of this study is to provide a series of guidelines for clinicians and surgeons to properly select the optimal tip geometries and speeds. Analytical models related to the cutting angles of several needle tip designs are presented and compared. Several needle tip geometries were manufactured from a 14-gauge cannula, commonly adopted during breast biopsies. The needles were then tested at different speeds and on different phantom tissues. According to these experimental measurements recommendations were formulated for rotating needle insertions. The findings of this study can be applied and extended to several biopsy procedures in which a cannula is used to extract tissue samples.

A novel piezoelectrically actuated 2-DoF compliant micro/nano-positioning stage with multi-level amplification.

This article presents a novel two-degrees-of-freedom (2-DoF) piezo-actuated parallel-kinematic micro/nano-positioning stage with multi-level amplification. The mirror symmetric stage consists of four leverage mechanisms, two Scott-Russell mechanisms, and a Z-shaped flexure hinge (ZFH) mechanism. Taking advantage of the ZFH mechanism, 2-DoF motions with final-level flexural amplification and decoupled motion guidance are achieved. Analytical models of the stage are developed and validated through finite element analysis to characterize its working performance. Practical testing of a prototype stage is conducted to demonstrate the design process and to quantify its response characteristics. Due to the utilized multi-level amplification, a practical amplification ratio of 13.0 is realized by the prototype. The decoupled output motion guidance feature of the stage makes it amenable for implementation in raster scanning type of measurements.

Effects of ultrasonic vibrations in micro-groove turning.

Ultrasonic vibration cutting is an efficient cutting process for mechanical micro-machining. This process can generate intricate surface textures with different geometric characteristics. Micro-grooves/micro-channels are among the most frequently encountered micro-structures and, as such, are the focus of this paper. The effectiveness of both the linear and ultrasonic elliptical vibration-assisted machining technique in micro-groove turning is analyzed and discussed in the paper. The paper first investigates the mechanisms of micro-groove generation induced by the linear and elliptical vibration modes. A simplified cutting force analysis method is given to compare the effectiveness of the two modes in micro-groove turning. The surface roughness of the generated micro-grooves is analyzed next and theoretical expressions are given for the two cases. Finally, micro-groove turning experiments are conducted to compare the influences of the two vibration modes on the cutting forces and the surface roughness. The experimental results show that linear vibration-assisted micro-groove turning leads to better surface roughness as compared to the elliptical vibration-assisted case, while elliptical vibration-assisted micro-groove turning shows advantages in terms of decreasing the cutting forces.

Laser-induced plasma in aqueous media: numerical simulation and experimental validation of spatial and temporal profiles.

A numerical study of spatial and temporal distribution of a Gaussian-pulsed laser-induced plasma in distilled water is conducted in order to understand the resulting electron density distribution within the plasma plume. The primary motivation behind this study is the recent impetus on laser-induced plasma in the field of microfabrication, where prediction of geometric feature information is paramount to understanding material removal and overall process performance. This simulation predicts the distribution of plasma energy density, absorption coefficient, and laser intensity within the focal region by using a 3D axisymmetric model. The model can be adapted to other nonaqueous condensed media and different laser wavelengths and pulse widths. This numerical model was experimentally validated by an ultrafast gated camera and an external power meter by measuring the plasma energy and residual intensity, respectively. The model and the experimental data show similar qualitative trends in plasma energy density as the beam power is increased. Also the residual intensity data obtained from the model is within 10% of the experimental data for near-threshold intensities and within 40% for super-threshold intensities. The outcomes of this model can be further used as an input for a hydrodynamic model to predict the behavior of the condensed medium or for a thermomechanical model to predict material removal characteristics of the plasma.

Study of the effect of cannula rotation on tissue cutting for needle biopsy.

Needle biopsy is a medical procedure to extract tissue for diagnosis of cancer and other diseases. The quality of tissue samples acquired by needle biopsy greatly depends on the cutting forces of the cannula. The reduction of cutting forces is crucial for obtaining good tissue samples. There exist many factors that influence the cutting forces, some of which include the cannula tip geometry, translation speed, and rotation speed. In the present paper, the effects of rotating the cannula on tissue cutting for needle biopsy are studied. A fracture-mechanics-based approach is used to analyze the cutting forces. Analysis has shown that the cutting forces decrease with the increases in the slice/push ratio defined as the ratio of speed component parallel to the cutting edge/speed perpendicular to the cutting edge. Experiments are performed to demonstrate this phenomenon. Mathematical models of the slice/push ratio for bevel tip cannulas are formulated. The results are used to determine the optimal cannula rotation/translation speed and the desired tip geometry for needle biopsy. It is shown that a minimal slice/push ratio of 2 is recommended. A cannula with a large bevel angle is more suitable for rotational needle biopsy.