Flexural Stiffness and Stresses in Nickel-Titanium Rotary Files for Various Pitch and Cross-sectional Geometries

Abstract Introduction Shape is the main determinant of mechanical performance for nickel-titanium rotary instruments. This study evaluated how pitch and cross-sectional geometry affected flexural stiffness and stresses. Methods Finite element models of rotary instruments with 4 cross-sectional geometries (triangle, slender-rectangle, rectangle, square) and 3 pitches (5-, 10-, 15-threads) were created, featuring superelastic nickel-titanium properties. All models had the same length, taper, and external peripheral radius; cross-sectional area and/or center-core area varied. The clamped shaft was rotated axially, while the tip was deflected 5 mm. Flexural stiffness and maximum von Mises stresses were calculated. Results Stiffness and maximum stress decreased with decreasing pitch (increasing threads). Doubling or tripling the threads for the triangular or rectangular cross sections decreased the stiffness and stress 6% and 12%, respectively; square cross sections were less affected (1% and 3% decrease, respectively). Square cross sections (higher cross-sectional and center-core areas) had higher stiffness and stresses than other models with same deflection. Rectangular and triangular models with the same center-core areas had similar stresses, but the rectangular model was 30%–40% stiffer. The slender-rectangle had the smallest center-core area and the lowest stiffness and stresses. Both rectangular cross sections caused stiffness and stress variations with rotation angle (13% for slender-rectangle); larger pitch caused more variation. Conclusions Under the same tip deflection (simulating canal curvature), flexural stiffness and stress correlated with center-core area. Increasing pitch increased flexural stiffness and stresses.