Azuddin Bin Mamat

Tribological investigation of diamond-like carbon coated micro-dimpled surface under bovine serum and osteoarthritis oriented synovial fluid

Abstract Osteoarthritis-oriented synovial fluid (OASF), i.e., that typical of a patient with osteoarthritis, has different physical and biological characteristics than bovine serum (BS), a lubricant widely used in biotribological investigations. Micro-dimpled and diamond-like carbon- (DLC) coated surfaces are key emerging interfaces for orthopedic implants. In this study, tribological performances of dimpled surfaces, with and without DLC coating, have been investigated under both BS and OASF. The friction tests were performed utilizing a pin on a disk tribometer, whereas contact pressure, speed, and temperature were simulated to a ‘medium walking gait’ of hip joint conditions. The mechanical properties of the specimen and the physical properties of the lubricant were characterized before the friction test. Raman analysis was conducted to identify the coating condition both before and after the test. The DLC-coated dimpled surface showed maximum hardness and residual stress. A DLC-coated dimpled surface under an OASF lubricated condition yielded a lower friction coefficient and wear compared to those of plain and dimpled specimens. The higher graphitization of coated materials with increasing load was confirmed by Raman spectroscopy.

Fabrication and characterization of DLC coated microdimples on hip prosthesis heads

Diamond like carbon (DLC) is applied as a thin film onto substrates to obtain desired surface properties such as increased hardness and corrosion resistance, and decreased friction and wear rate. Microdimple is an advanced surface modification technique enhancing the tribological performance. In this study, DLC coated microdimples were fabricated on hip prosthesis heads and their mechanical, material and surface properties were characterized. An Electro discharge machining (EDM) oriented microdrilling was utilized to fabricate a defined microdimple array (diameter of 300 µm, depth of 70 µm, and pitch of 900 µm) on stainless steel (SS) hip prosthesis heads. The dimpled surfaces were then coated by hydrogenated amorphous carbon (a-C:H) and tetrahedral amorphous carbon (Ta-C) layers by using a magnetron sputtering technology. A preliminary tribology test was conducted on these fabricated surfaces against a ceramic ball in simulated hip joint conditions. It was found that the fabricated dimples were perpendicular to the spherical surfaces and no cutting-tools wear debris was detected inside the individual dimples. The a-C:H and Ta-C coatings increased the hardness at both the dimple edges and the nondimpled region. The tribology test showed a significant reduction in friction coefficient for coated surfaces regardless of microdimple arrays: the lowest friction coefficient was found for the a-C:H samples (µ = 0.084), followed by Ta-C (µ = 0.119), as compared to the SS surface (µ = 0.248).

Mechanism and Design Analysis of Articulated Ankle Foot Orthoses for Drop-Foot

Robotic technologies are being employed increasingly in the treatment of lower limb disabilities. Individuals suffering from stroke and other neurological disorders often experience inadequate dorsiflexion during swing phase of the gait cycle due to dorsiflexor muscle weakness. This type of pathological gait, mostly known as drop-foot gait, has two major complications, foot-slap during loading response and toe-drag during swing. Ankle foot orthotic (AFO) devices are mostly prescribed to resolve these complications. Existing AFOs are designed with or without articulated joint with various motion control elements like springs, dampers, four-bar mechanism, series elastic actuator, and so forth. This paper examines various AFO designs for drop-foot, discusses the mechanism, and identifies limitations and remaining design challenges. Along with two commercially available AFOs some designs possess promising prospective to be used as daily-wear device. However, the design and mechanism of AFO must ensure compactness, light weight, low noise, and high efficiency. These entailments present significant engineering challenges to develop a new design with wide consumer adoption.

COMPUTER AIDED DESIGN AND FABRICATION OF A CUSTOM ARTICULATED ANKLE FOOT ORTHOSIS

Traditional design and manufacturing methods of ankle foot orthosis (AFO) involve manual techniques e.g., casting and molding of the limbs and often depend on trial and error. Three-dimensional scanning allows computer aided design (CAD) tools to be incorporated, however, both approaches rely on the external model of the limb. To design AFO with articulated joint, precise alignment of mechanical and anatomical joint axes is imperative. It is difficult to infer joint axis from external model as it is partially specified by the skeletal structure. In this article, a computer integrated design approach of an articulated AFO has been demonstrated. CAD model of the AFO was developed for a healthy subjects left leg based on the 3D models of skeleton and soft tissue of the limb. Components of the AFO were fabricated by rapid prototyping and CNC machining. The design approach is faster than the traditional techniques and also facilitates exact positioning of articulated ankle joint. The gait analysis indicates that the subjects ankle had to overcome lesser resistance with the custom made AFO compared to a pre-fabricated AFO. Simultaneous viewing of exterior and skeletal geometry might help the clinicians modify the design to enhance performance of the orthotic.

Effect of GMAW-CMT heat input on weld bead profile geometry for freeform fabrication of aluminium parts

In developing a new method for weld based freeform fabrication, parameter affecting the geometry of single-pass need to be determined as it has great influence on dimensional accuracy and mechanical property of metallic part. In this paper, profile geometry and microstructure of single pass weld bead developed using Gas Metal Arc Welding Cold Metal Transfer (GMAW-CMT) was investigated. Observation on cross sectional weld bead indicates GMAW-CMT has capability to produce free spatter and crack defect weld bead. Profile geometry measurement shows weld bead develop at higher heat input has width size larger than the weld bead develop at lower heat input. Microstructure examination in the substrate reveals formation of columnar dendritic, cellular and planar structure while at buildup layer exhibit equiaxed dendritic structure

Experimental and Theoretical Investigation of Powder–Binder Mixing Mechanism for Metal Injection Molding

Metallic powder and binder mixing mechanism plays a vital role in the quality of molded parts in metal injection molding. The present study is intended for experimental and theoretical investigation of powder–binder mixing mechanism to investigate the functional correlation among mixing parameters and performance characteristics for different composition of feedstocks. Powder loading and shear rate are considered as input parameter. Fuzzy expert system is adopted to test the validity of the experimental results by analyzing different numerical error criteria using the viscosity as output with respect to input parameters. The mean relative error and correlation coefficient for type A and type B were found to be 6.09% and 8.51% (<10%) and 0.990 and 0.998, respectively. Hence the result indicates a reliable acceptability of the proposed amount of powder loading for feedstock preparation.

Predicting the colour properties of viscose knitted fabrics using soft computing approaches

Abstract The aim of this paper was to predict the colour strength of viscose knitted fabrics by using fuzzy logic (FL) model based on dye concentration, salt concentration and alkali concentration as input variables. Moreover, the performance of fuzzy logic (FL) model is compared with that of artificial neural network (ANN) model. In addition, same parameters and data have been used in ANN model. From the experimental study, it was found that dye concentration has the main and greatest effects on the colour strength of viscose knitted fabrics. The coefficient of determination (R2), root mean square (RMS) and mean absolute errors (MAE) between the experimental colour strength and that predicted by FL model are found to be 0.977, 1.025 and 4.61%, respectively. Further, the coefficient of determination (R2), root mean square (RMS) and mean absolute errors (MAE) between the experimental colour strength and that predicted by ANN model are found to be 0.992, 0.726 and 3.28%, respectively. It was found that both ANN and FL models have ability and accuracy to predict the fabric colour strength effectively in non-linear domain. However, ANN prediction model shows higher prediction accuracy than that of Fuzzy model.

The impact of surface and geometry on coefficient of friction of artificial hip joints

Coefficient of friction (COF) tests were conducted on 28-mm and 36-mm-diameter hip joint prostheses for four different material combinations, with or without the presence of Ultra High Molecular Weight Polyethylene (UHMWPE) particles using a novel pendulum hip simulator. The effects of three micro dimpled arrays on femoral head against a polyethylene and a metallic cup were also investigated. Clearance played a vital role in the COF of ceramic on polyethylene and ceramic on ceramic artificial hip joints. Micro dimpled metallic femoral heads yielded higher COF against a polyethylene cup; however, with metal on metal prostheses the dimpled arrays significantly reduced the COF. In situ images revealed evidence that the dimple arrays enhanced film formation, which was the main mechanism that contributed to reduced friction.

Predicting the Mechanical Properties of Viscose/Lycra Knitted Fabrics Using Fuzzy Technique

The main objective of this research is to predict the mechanical properties of viscose/lycra plain knitted fabrics by using fuzzy expert system. In this study, a fuzzy prediction model has been built based on knitting stitch length, yarn count, and yarn tenacity as input variables and fabric mechanical properties specially bursting strength as an output variable. The factors affecting the bursting strength of viscose knitted fabrics are very nonlinear. Hence, it is very challenging for scientists and engineers to create an exact model efficiently by mathematical or statistical model. Alternatively, developing a prediction model via ANN and ANFIS techniques is also difficult and time consuming process due to a large volume of trial data. In this context, fuzzy expert system (FES) is the promising modeling tool in a quality modeling as FES can map effectively in nonlinear domain with minimum experimental data. The model derived in the present study has been validated by experimental data. The mean absolute error and coefficient of determination between the actual bursting strength and that predicted by the fuzzy model were found to be 2.60% and 0.961, respectively. The results showed that the developed fuzzy model can be applied effectively for the prediction of fabric mechanical properties.

Improving Surface Smoothness of Aluminium Alloys Multi-Bead Weld for Welding Rapid Forming Application

Understanding the interference of multi-bead parameters on surface smoothness is essential for accuracy of the formed parts made by welding rapid forming. This paper presents an investigation on surface smoothness of multi-bead aluminium alloys. Deposition path planning and overlap ratio is manipulated in order to improve surface smoothness. Observation on bead cross section indicates that deposition path planning has remarkable effect on the surface smoothness. Multi-bead that developed using continuous path planning has surface smoothness of 0.46 mm – 1.34 mm and most bead present wavy type surfaces. The surface smoothness is improved by increasing the overlap ratio. Meanwhile, skip path planning produced good surface smoothness of 0.11 mm – 0.28 mm. An improved surface smoothness featuring flat surface type is obtained with this path planning.