The use of ultrasonic vibrations to reduce the temperature and force in bone drilling is one of the most important advanced processes that have attracted the attention of bone surgeons. In this paper, the influence of the process parameters on temperature variations and force changes were investigated using response surface methodology (RSM). Moreover, using the statistical method of Sobol sensitivity, the effect of each input factor on and its sensitivity to temperature and force were studied. Simultaneous optimisation was also performed to achieve the lowest temperature and force in the minimum time of the bone drilling. The results showed that the main parameters influencing the temperature were rotational speed, vibration amplitude (33%) and feed rate (19%). The vibration amplitude, rotational speed, and feed rate, explaining 48%, 40%, and 12% of the variations, had the most significant effects on force in the ultrasonic-assisted bone drilling, respectively.
