Barbara Reggiani

Finite-Element Modeling of Bones From CT Data: Sensitivity to Geometry and Material Uncertainties

The aim of this paper is to analyze how the uncertainties in modelling the geometry and the material properties of a human bone affect the predictions of a finite-element model derived from computed tomography (CT) data. A sensitivity analysis, based on a Monte Carlo method, was performed using three femur models generated from in vivo CT datasets, each subjected to two different loading conditions. The geometry, the density and the mechanical properties of the bone tissue were considered as random input variables. Finite-element results typically used in biomechanics research were considered as statistical output variables, and their sensitivity to the inputs variability assessed. The results showed that it is not possible to define a priori the influence of the errors related to the geometry definition process and to the material assignment process on the finite-element analysis results. The errors in the geometric representation of the bone are always the dominant variables for the stresses, as was expected. However, for all the variables, the results seemed to be dependent on the loading condition and to vary from subject to subject. The most interesting result is, however, that using the proposed method to build a finite-element model of a femur from a CT dataset of the quality typically achievable in the clinical practice, the coefficients of variation of the output variables never exceed the 9%. The presented method is hence robust enough to be used for investigating the mechanical behavior of bones with subject-specific finite-element models derived from CT data taken in vivo

Sensitivity of the primary stability of a cementless hip stem to its position and orientation

Using computed tomography (CT)-based preoperative planning software, we can define with good accuracy the position of a cementless hip stem inside the host bone, but previous studies suggest that the pose the surgeon achieves during freehand surgery may differ from the planned one even by some millimeters. Advances in simulation now make it possible to predict the primary stability of the stem in a given position during the preoperative planning, but is the stability predicted for the planned pose indicative of that we can expect for the achieved pose? The aim of the present study was to verify how this prediction is affected by the differences observed between the planned and the achieved poses. Two finite element models of an implanted femur were generated, one with the stem in the planned pose, and one with the stem in the achieved pose, as defined from postoperative CT scans. When compared to experimental measurements, the model with the achieved position was clearly more accurate (0.6 vs. 12% error over measured peak micromotion); however, the predictions of induced micromotions were different between the two models for less than 13%. It is thus concluded that while the implant position does have an effect on primary stability, the estimate of micromotion we can get from the planned position remains a clinically relevant indicator.

Constitutive Laws for the Deformation Estimation of Extrusion Die in the Creep-Fatigue Regime

Tools are exposed to severe working conditions during the hot extrusion process. In particular, dies and mandrels can be subjected to an excessive amount of deformation as a result of the developed high cyclic loads and temperatures. In this scenario, a physical experiment reproducing the thermo-mechanical conditions of a mandrel in a porthole die was performed with the Gleeble machine on the AISI H11 tool steel with the aim to investigate the mechanisms that influence the die deformation. The design of experiment consisted of 4 levels of temperature, 3 levels of stress and 3 types of load, i.e. pure creep, pure fatigue and creep-fatigue. In all the testing conditions, a comparable pattern of the mandrel displacement-time curve was found reproducing the 3 stages of softening typical of the strain evolution in a standard creep test but with a marked primary phase. Thus, with the aim to identify an easy-applicable equation to estimate the die deformation, the time hardening creep law was chosen. Coefficients of the time-hardening law were optimized, for each testing condition, on the basis of experimental data starting from values for similar alloys taken from the literature. Results in terms of mandrel displacement were then compared to experimental data for the creep-fatigue condition at different stress and temperature levels. The values found were validated against additional experimental data performed with different specimen geometries. A good average agreement was found between experimental and numerical results. The developed procedure was then applied to an industrial die.

Prediction of Fibrous and Recrystallized Structures in 6xxx Alloy Extruded Profiles

The final microstructure of extruded profiles is of great importance for final mechanical properties and, consequentially, the ability to control and predict it is of extreme interest for Academic and Industrial researchers. In the paper a combined model, able to discern recrystallized areas respect to fibrous structures within the same profile, is initially proposed then validated through FEM implementation on an experimental campaign performed by Parson [1]. The model was tested under different die geometries and process conditions and a qualitative comparison with final microstructure obtained in the extrusion of a simple aluminum rod was performed.

Effect of Process Parameters on Seam Weld Quality of ZM21 Tubes

The increasing attention to magnesium alloys in extruded profiles, especially in the transportation industry, is related to their low density associated with good mechanical properties and complete recyclability. This allows to push towards both increasing efficiency and pollution restrictions. However, these advantages are negatively balanced by the production rates drop in relation to dangerous profile temperatures increasing that force to keep low velocities. In this context, a novel porthole die has been purposely designed for magnesium alloys allowing an increasing of the process velocity up to four times with respect to past solutions. The mandrel consisted of three ports made by 120° bridges that created an equal number of seam welds. The extruded tubes, made in ZM21, were 50 mm in diameter and 2 mm in thickness and were tested under different process conditions. In the present work, the quality of the seam welds has been investigated in relation to each process condition by means of the rubber plug testing method that allowed to applied an hydrostatic tensile state.

Effect of Liquid Nitrogen Die Cooling on Extrusion Process Conditions

In the paper, a die for the production of a complex hollow profile made by AA6060 alloy on an industrial 2500 ton press has been manufactured and tested under strict monitored conditions. In particular 5 thermocouples were placed in proximity of interesting positions inside the die: 3 next to the bearings and two near the welding chambers. A self-calibrated pyrometer was used for the temperature monitoring of profile. Press loads, ram speeds and container temperatures were continuously recorded directly from the press system. Six billets were initially extruded in order to reach a steady state condition being the last three used as industrial benchmark for the 2011 edition of the ICEB conference. Then the nitrogen was completely and partially opened and the evolution of the temperature in the die and in the profile recorded together with the process load. The effect on bearing temperature was extreme, in particular in proximity of nitrogen inlet, while almost no change in welding chamber thermocouples and in the process load was revealed.

Creep-Fatigue Interaction in the AISI H11 Tool Steel

The effect of process parameters on the creep-fatigue behavior of a hot-work tool steel for aluminum extrusion die was investigated through a technological test in which the specimen geometry resembled the mandrel of a hollow extrusion die. Tests were performed on a Gleeble thermomechanical simulator by heating the specimen using joule’s effect and by applying cyclic loading up to 6.30 h or till specimen failure. Displacements during the tests at 380, 490, 540 and 580°C and under the average stresses of 400, 600 and 800 MPa were determined. A dwell time of 3 min was introduced during each of the tests to understand the creep behavior. The results showed that the test could indeed physically simulate the cyclic loading on the hollow die during extrusion and reveal all the mechanisms of creep-fatigue interaction.

Evaluating the Flexural Stiffness of Compliant Hinges Made With Close-Wound Helical Springs

Advantages and problems related to the use of compliant hinges in articulated robotic structures are briefly discussed. A novel kind of elastic joint made with close-wound helical springs is then described. It is capable of large angular displacement so that it can be conveniently applied in manipulation devices like the humanoid robot hand developed at the University of Bologna. The results of this application encourage a systematic investigation on the properties of this kind of joints, not previously described in the literature, aiming at mechanical characterization and definition of design criteria. To this purpose, the paper outlines a general investigation programme, where theoretical models, Finite Elements analysis and experiments jointly contribute to the evaluation of the hinge stiffness and to the identification of influential design parameters. Preliminary results related to evaluation of the stiffness about the principal bending axis are then examined and discussed, comparing the results obtained from experiments with those achieved by means of a simplified mathematical model and the correspondent FE analysis. An auxiliary parameter is finally introduced in order to define a general criterion for the design of spring-based hinges subjected to large deflection.© 2006 ASME

A Numerical Modelling Approach for Time-Dependent Deformation of Hot Forming Tools under the Creep-Fatigue Regime

The present study was aimed at predicting the time-dependent deformation of tools used in hot forming applications subjected to the creep-fatigue regime. An excessive accumulated plastic deformation is configured as one of the three main causes of premature failure of tools in these critical applications and it is accumulated cycle by cycle without evident marks leading to noncompliant products. With the aim of predicting this accumulated deformation, a novel procedure was developed, presented, and applied to the extrusion process as an example. A time-hardening primary creep law was used and novel regression equations for the law’s coefficients were developed to account not only for the induced stress-temperature state but also for the dwell-time value, which is determined by the selected set of process parameters and die design. The procedure was validated against experimental data both on a small-scale extrusion die at different stress, temperature, load states, and for different geometries and on an industrial extrusion die which was discarded due to the excessive plastic deformation after 64 cycles. A numerical-experimental good agreement was achieved.

Comparison of Bulge Test vs. Conical Expansion Test for Hollow Extruded Profile Characterization

An experimental campaign on a tubular hollow profile, extruded in industrial environment at two ram speeds, was performed to compare two testing methodologies used for the assessment of the seam welds strength: the cone expansion and the bulge tests. In the former, a cone-shaped punch is driven into the tube causing the expansion till the specimen fracture; in the latter, an internal rubber plug is used to expand the specimen allowing to apply an hydrostatic tensile state. Results and repeatability of the two tests were analyzed in terms of loads and tube radius elongations at fracture; location and morphology of the fracture were also inspected. In each condition, and for both tests, ductile fractures appeared at seam weld location. The bulge test showed a significant reduced data scattering if compared to the cone test and provided more conservative outcomes in terms of elongation at fracture; in addition, it marked more prominently the effect of the increased ram speed that promoted a weld strength decay.