Investigating of Manufacturing of Titanium Hip Prosthesis by Cold Forging Process via FEM Analysis

Subject Areas :

Mohammad Mahdieh ¹ , Farshad Nazari ² , Khalid Shleej Zayed ³ , Fatemeh Aghoun ⁴

1 -
2 -
3 -
4 -

Received: 2024-07-29 Accepted : 2024-09-16 Published : 2024-12-23

Keywords: Cold Forging, FEM, ABAQUS Simulation, Hip Prosthesis, Titanium Alloy,

Abstract :

The forging process is a typical process to manufacture industrial parts that are subjected to fatigue stresses. The forged parts have equiaxial grains, and crack propagation occurs at a lower rate.  A part's mechanical properties stem from its manufacturing process and initial materials. One of the applications of the forging process is manufacturing different kinds of metallic prostheses such as hip prostheses, which are very privileged in medical and rehabilitating issues. Hip prostheses undergo various types of stress, i.e., fatigue stress, indicating its significance in manufacturing. Cold forging is a promising method to produce high-strength parts with high fatigue life. Titanium alloys are widely used in prostheses due to their corrosion resistance. This study investigates the feasibility of manufacturing hip prostheses via cold forging. To analyze the behavior of materials during the forging process, the FEM simulation by ABAQUS software is applied. The press force is a significant factor in achieving the final geometry in which raw material fills the forging die within one stroke. In addition, the strength of the die is noticeable during the forging process.   

 

References:

[1] Fiorentino, A., Zarattini, G., Pazzaglia, U. and Ceretti, E. 2013. Hip Prosthesis Design. Market Analysis, New Perspectives and an Innovative Solution. Procedia CIRP. 5:310–314. doi: 10.1016/j.procir.2013.01.061.
[2] Viceconti, M., Testi, D., Gori, R., Zannoni, C., Cappello, A. and De Lollis, A. 2001. HIDE: A New Hybrid Environment for the Design of Custom-Made Hip Prosthesis. Computer Methods and Programs in Biomedicine. 64(2):137–144. doi: 10.1016/s0169-2607(00)00097-3.
[3] Dall'Ava, L., Hothi, H., Di Laura, A., Henckel, J. and Hart, A. 2019. 3D Printed Acetabular Cups for Total Hip Arthroplasty: A Review Article. 9(7):729. doi: 10.3390/met9070729.
[4] Gentile, D., Di Bona, R., Vanoli, G., Testa, G. and Ricci, S. 2024. Integrated FEM-Multibody Co-Simulation of Additively Manufactured Hip Prosthesis containing cracks. Frattura ed Integrità Strutturale. 19:108-123. doi: 10.3221/IGF-ESIS.71.09.
[5] Mahdieh, M. 2019. Recast Layer and Heat-Affected Zone Structure of Ultra-Fined Grained Low-Carbon Steel Machined by Electrical Discharge Machining. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 234. doi: 10.1177/0954405419889202.
[6] Mahdieh, M. and Mahdavinejad, R. 2016. Recast Layer and Micro-Cracks in Electrical Discharge Machining of Ultra-fine-grained Aluminum. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 232. doi:10.1177/0954405416641326.
[7] Mahdieh, M., and Zare Reisabadi, S. 2019. Effects of Electro-Discharge Machining Process on Ultra-Fined Grain Copper. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 233. doi: 10.1177/0954406219844802.
[8] Mahdieh, M. S. and Mahdavinejad, R. A. 2016. Comparative Study on Electrical Discharge Machining of Ultrafine-grain Al, Cu and Steel. Metallurgical and Materials Transactions A. 47(12):6237-6247. doi: 10.1007/s11661-016-3741-y.
[9] Mahdieh, M. and Zare Reisabadi, S. 2019. Effects of Electro-Discharge Machining Process on Ultra-Fined Grain Copper. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 233. doi: 10.1177/0954406219844802.
[10] Mahdieh, M. S. 2020. The Surface Integrity of Ultra-Fine Grain Steel. Electrical discharge machined using Iso-pulse and resistance–capacitance-type generator. 234(4):564-573. doi: 10.1177/1464420720902782.
[11] Mahdieh, M. S. 2023. Improving Surface Integrity of Electrical Discharge Machined Ultra-Fined Grain Al-2017 by Applying RC-type Generator. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. doi: 10.1177/09544089231202329.
[12] Risse, L., Woodcock, S., Brüggemann, J. P., Kullmer, G. and Richard, H. 2022. Stiffness Optimization and Reliable Design of a Hip Implant by Using the Potential of Additive Manufacturing Processes. BioMedical Engineering OnLine. doi: 10.1186/s12938-022-00990-z.
[13] Tagimalek, H., Maraki, M., Mahmoodi, M. and Zadeh, P. 2021. Investigation Experimental and Finite Element Method of Mechanical Properties of Hot Forging on Ti6Al4V Alloy. Iranica Journal of Energy & Environment. doi: 10.5829/ijee.2021.12.02.07.
[14] Park, N. K., Yeom, J. T. and Na, Y. S. 2002. Characterization of Deformation Stability in Hot Forging of Conventional Ti–6Al–4V Using Processing Maps. Journal of Materials Processing Technology. doi: 10.1016/S0924-0136(02)00801-4.
[15] Levkulich, N., Semiatin, S. L. and Payton, E. 2021. An Investigation of the Development of Coarse Grains during β Annealing of Hot-Forged Ti-6Al-4V. Metallurgical and Materials Transactions A . 52(4):1353-1367. doi: 10.1007/s11661-021-06158-z.
[16] Tomczak, J., Pater, Z. and Bulzak, T. 2015. Forming of Hollow Shaft Forging from Titanium Alloy Ti6Al4V by Means of Rotary Compression. Archives of Metallurgy and Materials . 60(1):419-425. dio: 10.1515/amm-2015-0069.
[17] Mahdieh, M., Nazari, F., Mussa, T. and Salehi, H. 2023. A Study on Stamping of Airliner's Tail Connector Part Through FEM Simulation. 15:5-13. doi: 10.71939/jsme.2023.1092088.
[18] Mahdieh, M. S. and Monjezi, A. 2020. Investigation of an Innovative Cleaning Method for the Vertical Oil Storage Tank by FEM Simulation. Iranian Journal of Materials Forming. doi: 10.22099/ijmf.2022.43842.1229.
[19] Mahdieh, M., Nazari, F. and Khairullah, A. 2023. A Study on The Effects of Different Pad Materials on Brake System Performance of a High-Capacity Elevator by FEM Simulation. 16:61-68. doi: 10.30486/ADMT.2024.2001757.1426.
[20] Yeom, J. T., Park, N. K., Lee, Y. H., Taejin, S., Hong, S., Shim, O., Hwang, S. M. and Lee, Ch. 2005. Process Design of Isothermal Forging for Three-Dimensional Ti-6Al-4V Wing-Shape. Transactions of Materials Processing. doi: 14. 10.5228/KSPP.2005.14.2.126.
[21] Gontarz, A., Pater, Z. and Tofil, A. 2011. Numerical Analysis of Unconventional Forging Process of Hollowed Shaft from Ti-6Al-4V Alloy. Journal of Shanghai Jiaotong University (Science). doi: 16. 157-161. 10.1007/s12204-011-1118-3.
[22] Luo, S., Zhu, D., Qian, D., Hua, L., Yan, S. and Zhang, J. 2015. Effects of Friction Model on Forging Process of Ti-6Al-4V Turbine Blade Considering the Influence of Sliding Velocity. International Journal of Advanced Manufacturing Technology. doi: 10.1007/s00170-015-7538-8.
[23] Mahdieh, M. S., BakhshiZadeh, M. and Zare Reisabadi, A. H. 2023. Improving Surface Roughness in Barrel Finishing Process Using Supervised Machine Learning. Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering . 15(2):5-15. Doi: 20.1001.1.27834441.2023.15.2.1.0.
[24] Vakili Sohrforozani, A., Farahnakian, F., Mahdieh, M. S., Behagh, A. M. and Behagh, O. 2020. Effects of Abrasive Media on Surface Roughness in Barrel Finishing Process. ADMT Journal . 13(3):75-82.doi: 10.30495/admt.2020.1889912.1165.
[25] Saraeian, P., Gholami, M. and Mahdieh, M. S. 2016. The Influence of Vibratory Finishing Process by Incorporating Abrasive Ceramics and Glassy Materials on the Surface Roughness of CK45 Steel 9.
[26] Zhu, Y., Zeng, W., Ma, X., Tai, Q., Li, Z. and Li, X. 2011. Determination of the Friction Factor of Ti6Al4V Titanium Alloy in Hot Forging by Means of Ring-Compression Test Using FEM. Tribology International - TRIBOL INT.44:2074-2080.doi: 10.1016/j.triboint.2011.07.001.
[27] Park, N. K., Yeom, J. T. and Na, Y. S. 2002. Characterization of Deformation Stability in Hot Forging of Conventional Ti–6Al–4V Using Processing Maps. Journal of Materials Processing Technology. 130-131. 540-545. doi: 10.1016/S0924-0136(02)00801-4.
[28] Odenberger, E. L., Oldenburg, M., Thilderkvist, P., Stoehr, T., Lechler, J. and Merklein, M. 2011. Tool Development Based on Modelling and Simulation of Hot Sheet Metal Forming of Ti–6Al–4V Titanium Alloy. Journal of Materials Processing Technology. 211:1324–1335. doi:10.1016/j.jmatprotec.2011.03.001.
[29] Ahmadi, H. and Zohoor, M. 2017. Investigation of the Effective Parameters in Tube Hydroforming Process by Using Experimental and Finite Element Method for Manufacturing of Tee Joint Products. The International Journal of Advanced Manufacturing Technology.93:1-2. doi: 10.1007/s00170-016-9690-1.
[30] Li, J. F., PENG, Z. W., L. I., C. X., Peng, Q. Z., CHEN, W. J. and ZHENG, Z. Q. 2008. Mechanical Properties, Corrosion Behaviors and Microstructures of 7075 Aluminium Alloy with Various Aging Treatments. Transactions of Nonferrous Metals Society of China. 18:755-762. doi: 10.1016/S1003-6326(08)60130-2.
[31] Besheli, S., Mazdak, S., Golmakani, H., Sharifi, E. and Sheykholeslami, M. 2018. Numerical and Experimental Investigation of Deep Drawing Process in Square Section of Single-Layer and Two-Layer Sheets.58-70. doi: 10.0.205.67/masm.2.2.172.
[32] Manafi, B. and Sefiddashti, S. 2023. Investigation of the Deformation Behavior of 7075 Aluminum Alloy under Backward Extrusion Process for Producing Conical parts.
[33] Moradi, A., Heidari, A., Amini, K., Aghadavoudi, F. and Abedinzadeh, R. 2022. The Computational Study of Number of Shot Particles and Distance Effects on Residual Stress and Mechanical Behavior of Ti-6Al-4V Alloy after Shot Peening Process: Molecular Dynamics Approach. 11:17-35. dor: 20.1001.1.27170314.2022.11.2.2.0.
[34] Shahmirzaloo, A., Faraji, G., Safari, M. and Mohammadinejad, S. 2018. Interface Sheet Constrained Groove Pressing as a Modified Severe Plastic Deformation Process. Materials Science and Technology. doi:10.1080/02670836.2018.1471379.
[35] Ahmadi, F., Abdollahi, A. and Zamani, S. 2023. Experimental Study of Shearing Dimensional Parameters in the Sheet Metal Blanking Process of StW24 Steel with a Thickness of 12 mm. Journal of Modern Processes in Manufacturing and Production. 12(2):5-21. doi: 20.1001.1.27170314.2023.12.2.1.6.
[36] Mahdieh, M. S. and Estek, M. R. 2022. Feasibility Investigation of Hydroforming of Dental Drill Body by FEM Simulation. Journal of Modern Processes in Manufacturing and Production. 11(2):71-83. doi: 20.1001.1.27170314.2022.11.2.7.5.
[37] Vakili Sohrforozani, A., et al. 2019. A Study of Abrasive Media Effect on Deburring in Barrel Finishing Process. Journal of Modern Processes in Manufacturing and Production. 8(3):27-39.
[38] Hou, X., Liu, Z., Wang, B., L. V., W., Liang, X. and Hua, Y. 2018. Stress-Strain Curves and Modified Material Constitutive Model for Ti-6Al-4V over the Wide Ranges of Strain Rate and Temperature. Materials (Basel, Switzerland). 11(6):938.doi: 10.3390/ma11060938.
[39] Behrens, B. A., Stonis, M., Blohm, T. and Richter, J. 2018. Investigating the Effects of Cross Wedge Rolling Preforming Operation and Die Forging with Flash Brakes on Forging Titanium Hip Implants. International Journal of Material Forming. doi: 11. 10.1007/s12289-016-1329-0.