Effect of repeated millings on the surface integrity of diamond burs and roughness of different CAD/CAM materials

Objectives This study evaluated the surface integrity of two types of diamond burs and their effect on the roughness of different CAD/CAM materials. Materials and methods CAD/CAM materials, Vita Mark II (VM), IPS e.max CAD (EM), Celtra Duo (CD), G-Ceram (GC), and Lava Ultimate (LU) blocks were milled with CEREC MCXL. Five pairs of pointed cylinder burs (CB) and step burs (SB) were used repeatedly. The wear rate of burs was analyzed before and after milling with a scanning electron microscope (SEM) and weighing the burs. The milling time of the blocks at different milling stages was recorded from 2 (M2) to 8 times (M8) of use. The surface roughness (Ra) of blocks was measured with a profilometer. Data from the differences in surface roughness were analyzed using univariate analyses of variance and Kruskal-Wallis tests (alpha = 0.05). Results For M2, the highest roughness (2.12 +/- 0.1 mu m) was observed with the VM block. EM blocks presented the highest roughness values (1.82 +/- 0.3 mu m, 1.85 + 0.1 mu m, and 1.86 +/- 0.04 mu m) at M4, M6, and M8, respectively. While the highest Ra values were observed for VM (2.12 to 1.43 mu m), LU provided the lowest mean Ra (1.62 to 1.33 mu m) among the tested materials. After the repeated use of burs up to 8 times, the surface roughness of all the tested materials decreased. Milling of LU resulted in chip deposits on the CB surface in SEM images. The duration of cutting was higher for CD and EM materials than those of other materials, but the milling duration for VM, GC, and LU blocks was similar. SB burs exhibited more wear than CB after repeated milling. Conclusions A repeated number of millings more than 4 times decreased the surface integrity of the milling burs, increased the surface roughness of CAD/CAM blocks except for LU, and increased the milling duration. Increased material hardness was more detrimental on bur surface integrity.