The bone drilling process is indispensable in orthopaedic surgeries and treating bone breakages. It is also very important in dentistry and bone sampling operations. Bone is a very complex material and the process of drilling is very sensitive. Thus, bone drilling is one of the most important, common in the field of biomedical engineering. The bone drilling process can be promoted using automatic drilling machines and surgery-assisting robots. The problematic issue during operation is the high increase in drilling process temperature (higher than 47 C) which leads to the so-called D1‘thermal necrosis’D2 or cell death, and local burn in bone tissue. Furthermore, imposing higher forces to bone might yield to breaking or cracking, and consequently causes serious damages in bone. In this paper, the tool rotational speed, feed ratio and tool diameter were taken into account as process input parameters, and process temperature and thrust force were taken as output parameters. Design of experiments using response surface methodology was followed. Then, second linear governing equation was assigned to the model and its accuracy was evaluated. Later, Sobol statistical sensitivity analysis was used to ascertain the effect of process input parameters on process temperature and force. The results showed that among all effective input parameters, the tool rotational speed, feed rate and tool diameter have the highest influence respectively on process temperature and force. The behaviour of each output parameter with variation in each input parameter was further investigated
