Dynamic Stresses and Deformations Investigation of the Below Knee Prosthesis using CT-Scan Modeling

Dynamic Stresses and Deformations Investigation of

the Below Knee Prosthesis using CT-Scan Modeling

Muhsin J. Jweeg

, Abdulkareem Abdulrazzaq Ahumdany

, Ali Faik Mohammed Jawad

_{Al-Farahidi University, Baghdad, Iraq, muhsinjj@gmail.com}

2

_{University of Babylon College of Engineering Al-Musayab, Iraq, Alhumdany@yahoo.com}

Mechanical Engineering Department, College of Engineering, University of Kerbala, Iraq, alialrafiya@gmail.com

Abstract

Index Term

I.

I

The modified for mechanical properties and behavior for

below knee prosthesis and socket part investigated from many

researchers at previous years. Therefore, more study gold to

increase strength for materials used for manufacturing the

socket. Then, can be using various way to modified the

mechanical properties and behavior for its parts, as, change the

reinforcement fiber types, change the reinforcement fiber

volume fraction, change the laminated sconces … etc.

Therefore, same researchers listing below shown same ways to

modified the strength and properties for materials used, as,

Firstly, M. J. Jweeg et. al, [1-3], from 2011 to 2017,

investigated the effect for materials properties changing on the

various mechanical properties and stress behavior for foot,

socket, and prosthetic below knee, in addition to, investigated

the creep and fatigue characterizations for materials used to

manufacture its parts, by using experimental and theoretical

techniques. After this, J. S. Chiad et. al, [4-5], at 2012 and

2018, investigated the vibration analysis for below knee and

stress distribution by using experimental techniques.

The, A. M. Takhakh et. al, [6-8], at 2013 and 2018, studied the

vibration and other mechanical properties and behavior for

various Orthosis part with various materials types parameters.

After this, J. K. Oleiwi, [9-10], at 2016 and 2018,

investigation the effect of materials properties with various

reinforcement effect on the stress analysis for various foot

and, prosthetic and biomechanical applications parts. Then, M.

A. Al-Shammari, [11-12], at 2017 and 2018, presented the

stress and fatigue analysis for knee prosthesis sockets with

various reinforcement materials effect experimentally. Also, at

2017, K. K. Resan, [13], investigated the effect of ultraviolet

radiation on the fatigue behavior of below-knee sockets, with

and with-out Heat effect, by using experimental technique.

Finally, M. Al-Waily, [14-17], at 2018, investigated for the

reinforcement fiber type effect on the various mechanical

behavior for foot and below knee, as stress and fatigue

behavior for materials used, in addition to, investigated the

tempratue effect on the fatigue behavior for foot part. Also,

the investigation included analysis for Biomechanical and gait

assessment for normal and Legs.

Therefore, in this work the ultimate tensile strength, the

modulus of elasticity and dynamic load factor for the

suggested marital will be determining. The material properties

will be inserted to the ANSYS 16.0. While the modelling of

the socket will be made by using CT-scan method.

When, the application of CT-Scan modeling has been used by

a few researches before, because of its difficulty. Diane Higgs

and Phavan Sanders [18] developed a design for below knee

prosthetic. The design was based on prescribed specification,

which includes manufacturing process, material, physical

actives data points were acquired from a CT scan of a residual

limb and allowance was made in pressure areas. Figure 1

shows the CT-scan slices for the tibia crest. The socket model

was imported into ANSYS 5.7 for finite element analysis.

Sam L. Phillips et al [19] Have made Eight varieties of lay-up

materials (fibers) each laminated separately with one of three

common resins (matrix), resulting in 24 combinations of

fiber/resin laminates. the weakest were laminates with fibers

of perlon or Nyglass stockinette, spectralon, nylon, and cotton,

ranging between 18 and 42 (MPa); the middle was fiberglass,

ranging between 67 and 109 MPa; the highest strengths were

found in carbon fiber laminates, ranging between 236 and 249

MPa. As shown in figure 2 (A and B) and figure 3 (A and B).

Fig.2 A: The average thickness for the sample set.

Fig. 2.B: The average weight for the sample set.

Fig. 3 A: Stress-strain curves for two samples

Fig. 3 B: Ultimate tensile strength of composites using three resins

II. EXPERIMENTAL PART

The experimental technique included manufacturing and

testing for the below knee structure with materials combined.

Where, the testing samples are manufacturing accordant to

ASTM stander, [20-29], with various composite combined

reinforcement effect.

The experimental part consists of manufacturing the below

knee prosthetics by using the following material and

equipment, knit from perlon, kevlar fibers, laminations resin

80:20 polyurethane, and, hardening powder.

II.1. Equipment of Manufacturing the Prosthetic Socket

Gypsum mold: Mold is made of gypsum material with an

external shape of parallelogram with dimensions of 12 cm 12

cm 30 cm. This mold underwent operations sculpt and refine

of the surface because the inner surface of the material to be

manufactured will take the form of the outer surface of the

mold see figure (4a). Vacuum system: It includes pipes and

vacuum pump. It is used for suction the air completely from

two possible gaps between the PVA and the gypsum mold and

between the inner and outer plies of PVA. There are several

benefits of vacuum system. In the first gap vacuuming gives a

perfect shape for gypsum mold and prevents creating bubbles

between the mold and PVA. For the second gap vacuum is

used to remove the air between the PVA and the part of

casting process. Moreover, vacuum process insures no bubbles

created during the casting process and insure the suitable

distribution of the risen throw all the layers figure (4b).

II.2 Procedure of Manufacturing Prosthetic Socket

The following steps were followed:

1.

Putting the first piece from the PVA on the gypsum molds

as shown in figure (2a) and suction the air between PVA

and gypsum by the vacuum system.

2.

Putting the first Knit of perlon as shown in figure (2b) that

density is 0.01331g /cm

3.

For available material Putting the mat from Kevlar fiber

with density is 1.44 g/cm

.

4.

Putting the second Knit of perlon that density is 0.01331

g/cm

and the second piece of PVA and suction the air

between two bags by the vacuum system. Mix the

laminations resin with hardening powder put this mixture

on these layers as distributed equally as shown in figure

(5d).

Fig 5: Procedure for made material of prosthetic socket

II.3. Tensile Test

yield stress and ultimate stress for each material used for

suggested prosthetic socket. Standard tensile test specimens

were cut from the final product according to the American

Society for Testing and Materials (ASTM) D638 [30-38].

Three specimens were cut for each lamination, [39-42], at the

workshop using a computer numeric control (CNC)

machine.as shown in figure 6 and figure 7.

Fig 6: Tensile test specimens and the dimensions for suggested material.

A. Before Testing B. After Testing

Fig 7: Tensile Test for suggestion material Before and After Test.

II.4. Free Vibration Test

The test can be Concisely into the following:

1.

The testing device consists of a special testing hammer,

accelerometer, amplifier and monitor as shown in Figure 8.

2.

The manufactured socket was fixed from the adaptor as a

boundary condition.

3.

The position of the nodes to be tested are marked as shown

in figure 9

4.

The testing hammer used to produce the natural frequency

by hitting the fixed socket a quick and strong hit; this

operation has been done fourth times for the same node but

the hit was in deferent direction.

5.

Finally, the frequency waves were recorded and saved in

USB flash memory.

Fig 8: The Natural Frequency Rig.

Fig 9: The markers of the tested nodes.

III. NUMERICAL ANALYSIS FOR BELOW KNEE

PROSTHETIC SOCKET

The finite element method (FEM) is extensively used in the

multi purposes fields in engineering and science, [43-51],

taking the advantage of the rapid development of digital

computers with large memory capacity, by fast computation.

The method is recognized as one of the most powerful

numerical methods because of its capabilities which include

complex geometrical boundaries and non-linear material

properties. In this work, FEM with the aid of ANSYS

workbench 16.0 software is used as a numerical tool to

illustrate the effect of the fatigue performance in a structure

element to determine the behavior of stress distributions

contour, total deformations, and areas of safety factor. The

general analysis by using ANSYS workbench version 16.0 has

three distinct steps they are, [52-58]:

1.

Building the geometry as a model.

2.

Applying the conditions of boundaries load and get the

solutions.

III.1. CT-Scan of the Below Knee Prosthesis

A below-knee amputee socket has been modeled by using

CT-scan method in AL-Kafeel hospital/kerbala/iraq, the obtaining

slice pictures from CT-Scan for the designed socket had been

exported to (Materialise Mimics Innovation Suite 17.0) where

the 3D modeling which created as shown in Figure 10. The

generated geometry was not uniform because of the stainless

steel adapter joint makes the X-Ray shuttering. As shown in

figure 11.

Fig.10: CT-scan generated geometry

Fig 11: The Shuttered Area Around the Socket Adapter

After making a lot of editing steps included erasing and

redrawing soothing and wrapping which makes the geometry

acceptable and ready to be analyzing, as in Fig. 12.

Fig. 12: The Final Shape of Socket. after editing.

III.2. Mesh of the Model

The meshing process has been done by choosing the volume,

and then the shape of element was selected as tetrahedron

(Automatic meshing), [59-70], for The prosthetic socket as

shown in figure 13. This meshing contains on 350000

elements according to, triangular method has been chosen

ANSYS elements and nodes counter.

Fig.13: The model of BK socket with meshing

IV. RESULT AND DISCUSSION

IV.1. Experimental Results

A.

Mechanical Properties

The mechanical properties as (σult and E) of each tested

spaceman material represent the average value for three

attempts are listed in Table. I. These properties will be used

later in the program ANSYS 16.0 to simulate the prosthetic

socket and analyze stress and deformation.

Table I

The mechanical properties of the material tested.

Material

suggested available

Ultimate stress σ ult (MPa)

177.9

33.65

Modulus of elasticity (E) (GPa)

1.87

0.941

B.

Natural Frequency Results

Natural frequency results were achieved at university of kuffa/

department of mechanical engineering, by testing ten different

positions and take the average results for each suggested node

it was about (69.3) as shown in figure (114) while the other

ten nodes result have listed in table II.

Table II

Ten Nods result for the socket

Nodes

No.

Natural Frequency (HZ)

1

68.665

2

69.275

3

69.58

4

67.749

5

70.496

6

`70.496

7

69.58

8

69.29

9

68.359

10

69.27

Average

69.276

C.

Gait Cycle Results

The results of a step for the two cases (available and suggested

socket) are summarized in Tables III and Table IV

respectively. The results include the prosthetic left leg (injured

leg) and right leg (intact leg) for two cases. For the step-strip

specification result the differences can be observed between

the injury leg and normal leg for the two cases (suggested and

available socket). The difference in the step length for the

suggested socket was (0 cm) while it was (6 cm) for the

available socket; this gives enhancement by (100 %). For the

step time difference, it was (0.02 sec) for the suggested socket

while it was (0.05 sec) for the available socket so it was

enhanced by (60%). Also the foot rotation angle difference for

first case was (0.9 deg), while its being (4.2 deg) for the

second case and thus it’s have been enhanced (78.5%).

The result that obtained in figure 15 and figure 16, have

shown that the difference in gait cycle length and single

support line was (10mm) and (4mm) respectively; for the

suggestion socket. While for the polypropylene socket it was

(37mm) and (47mm) respectively.

Table III

Step-Strip and gait cycle results for suggestion prostheses socket.

Table IV

Step-Strip specification and gait cycle results for available prostheses socket.

Fig 15: A) Gait line length. (B) Single support line, Anterior/posterior position and Lateral symmetry. For suggestion socket

Fig 16: (A) Gait line length. (B) Single support line, Anterior/posterior position and Lateral symmetry. for available socket.

IV.2. The Numerical Results

A.

Static Results

The equivalent Von-Mises Stresses analysis gives a

knowledge on the amounts of stress and deformation

generated by the interface pressure in the socket. The highest

stress value was 107 MPa in the socket made from the

suggested material as shown in figure (17) while the total

deformation was not exceeding 21 mm in some thin area as

shown in figure (18).

Fig. 17: Von-Mises stress of suggested prosthetic socket material

Fig. 18: Total deformation for suggested prosthetic socket material

B.

Dynamic Results

The dynamic analyses is the actual state for the all movement

application so to make that available for the prosthetics socket

it has been assumed to cases the first was subjected the socket

to unit step force its value was 700 N as shown in figure 19

(from the GRF test). The obtained results for the first case

showed that the maximum stress was 107 Mpa as shown in

figure (20). While the total deformation was 24 mm as shown

in figure (21). Also figure (22) and figure (23) showing the

stress and deformation verses time curves during one second.

Fig. 19: Unit Step force during 1 second for both sockets.

Fig. 20: The equivalent stress at the last second for the unit step force.

Fig. 21: The total deformation in the last second for the unit step force.

Fig. 22: Dynamic stresses during 1 second for the unit step force.

While in the second case it was assume that force as sinusoidal

as show in figure (24). The second case showed that the

maximum developed stress and deformation was 147 Mpa and

22 mm respectively at 0.8 second as shown in figure (25) and

figure (26). While the stress-time and deformation-time curve

s have shown in figure (27) and figure (28) respectively.

The dynamic load factor has been calculated by dividing the

dynamic stress on static stress

DLF= dynamic stress (MPa))/ (static stress (MPa)

It is find that DLF does not exceed (1.188) for the suggested

socket material.

Fig.24: Sinusoidal force during 1 second.

Fig.25: The maximum stress value at 0.8 second.

Fig 26: The deformation value at 0.8 second.

Fig. 27: Stress-time curve for the sinusoidal force.

Fig. 28: Deformation-time curve for the sinusoidal force.

V. CONCLUSIONS

The following points are concluded as follows,

1.

To have a uniform solidification the ambient temperature

should be more than 24o C for the lamination risen 80:20.

2.

The mechanical proprieties for the suggestion material (2

perlon +1 kevlar + 1 perlon +1 kevlar +2 perlon) show

better results than available material (polypropylene).

Where the ultimate tensile strength and modulus of

elasticity are increased by (428.6%) and (98.7%)

respectively.

3.

CT-scan method was very powerful in FEL modeling

geometry compared to the normal geometry representation

of the socket.

4.

From the gait cycle results, it was observed that the

suggested socket prostheses decrease the butterfly

parameters, the difference between the injury leg and the

intact leg. the butterfly parameters and the gait cycle step

time enhanced by (60 %).

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