Hot Forging Process Design and Initial Billet Size Optimization for Manufacturing of the Talar Body Prosthesis by Finite Element Modeling

Authors

  • Panuwat Soranansri Department of Teacher Training in Mechanical Engineering, Faculty of Technical Education, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand
  • Tanaporn Rojhirunsakool Department of Materials and Production Technology Engineering, Faculty of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand
  • Narongsak Nithipratheep Department of Mechanical Engineering Technology, College of Industrial Technology, King Mongkut’s University of Technology North Bangkok, Thailand
  • Chackapan Ngaouwnthong Department of Agricultural Engineering for Industry, Faculty of Industrial Technology and Management, King Mongkut’s University of Technology North Bangkok, Thailand
  • Kraisuk Boonpradit Center of Innovation in Design and Engineering for Manufacturing (Coi DEM), Science and Technology Research Institute, King Mongkut’s University of Technology North Bangkok, Thailand
  • Chawaphon Treevisootand Center of Innovation in Design and Engineering for Manufacturing (Coi DEM), Science and Technology Research Institute, King Mongkut’s University of Technology North Bangkok, Thailand
  • Walinee Srithong Center of Innovation in Design and Engineering for Manufacturing (Coi DEM), Science and Technology Research Institute, King Mongkut’s University of Technology North Bangkok, Thailand
  • Piyapat Chuchuay Materials and Production Engineering Program, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok, Thailand
  • Kumpanat Sirivedin Materials and Production Engineering Program, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok, Thailand

DOI:

https://doi.org/10.14416/j.asep.2021.01.002

Keywords:

Near net shape manufacturing, Medical prosthesis, CAD/CAM/CAE technologies

Abstract

In hot forging industry, the process design and the billet size determination are very crucial steps because those steps directly influence both the product quality and material utilization. The purpose of this paper was to propose a technique used to design the hot forging process for the manufacturing of the talar body prosthesis. The talar body prosthesis is one of the artificial bones, which its geometry is a free form shape. In this study, the Finite Element Modeling (FEM) was used as a tool to verify the proposed design before implementation in a production line. In addition, an initial billet was determined the optimum size in the FEM by varying the mass ratio factor, the diameter, and the length. It was found that the mass ratio factor is a very useful guideline since the optimum size is quite close to the provided size from the guideline. The FEM results showed that the dimensions of the initial billet significantly affect the complete metal filling in the die cavity. Moreover, the optimum size between the diameter and length can reduce the material waste in the hot forging process of the talar body prosthesis. Finally, the experimental results of the hot forging process showed that the proposed process design with the optimum size of the initial billet is achieved in order to manufacture the talar body prosthesis and the material utilization of the new proposed process is improved from the traditional process by 2.6 times.

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References

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Published

2021-10-20

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Section

Research Articles