Degree Type


Date of Award


Degree Name

Master of Science


Industrial and Manufacturing Systems Engineering


Industrial Engineering

First Advisor

Mathhew C. Frank


This thesis focuses on a new method to reduce surface smearing caused by machining metal-lic foams. Metallic foam is a cellular structure, similar to foam, but made of metal. This study demonstrates a new method which uses ice as an infiltrant, built upon previous work which used wax as an infiltrant. Ice as an infiltrant helps cell walls by providing them support. In this study, experiments were conducted on a metallic foam named Trabecular Metal™ (TM). It is made of elemental tantalum (Ta) which is one of the most chemically stable and biologi-cally inert materials. This specific characteristic of Ta makes it suitable for orthopedic metal implants. Research tasks include replication of the results from previous methods (using wax as an infiltrant), and then proof of concept for ice as a suitable material for infiltrant. All ma-chining trials on ice infiltrated TM were conducted in a cryogenic environment. It avoided melting of ice due to excessive heat produced because of machining process. The final task includes optimization of the significant process parameters to make it faster and efficient. Re-sults indicated that the use of ice as an infiltrant worked as well as wax; while also reducing the possibility of having any detrimental residue left inside the implant. By analyzing statis-tics on collected data, it was also concluded that feed rate is the most significant factor to re-duce the surface smearing of metallic foam, Spindle Speed and Corner Radius were also shown to have a significant effect. The impact of this research is that it will help to machine metallic foams more efficiently than before, now with an inert infiltrant materials that is easy to remove after processing.


Copyright Owner

Vishal Vijaykumar Mane



File Format


File Size

70 pages