Development of an Effective Uncemented Femoral Stem Implant with CNC Ball End Milling

SADANANDA CHAKRABORTY, BIDHAN CHANDRA BISWAS, NIRMAL KUMAR MANDAL

Abstract


Now a days uncemented total hip replacement (THR) is mostly used in surgery of hip joint. Quality and reliability of an uncemented femoral stem depends on many factors. The effect of roughness of the implant on the stress distribution, Von Mises Stress of the implanted femur with varying frictional co-efficient ranges from 0.2 to 0.4 have been studied through finite element analysis using commercial finite element analysis package ANSYS. Machining of the implant is very important because there are so many factors likes, quality of the product, combination of tool-work piece material, machinability of the work material, productivity etc that depends on performance. The aim of the present study is to find out the optimum significant parameters of the machining operation of femoral stem implant for optimum surface roughness. SS316L has been taken as the work material as it is widely used as hip implant. Ball end milling cutter of coated carbide has been chosen as the cutting tool as it is used in the finish cut of complex shapes. Speed, feed rate and Step over are taken as the cutting parameters. MINITAB 16 commercial software package is used to determine the number of experiment through Design of Experiment (DOE). Total 20 no. of experiments are conducted and the collected data are analyzed to predict the surface roughness through regression analysis. Significance of input process parameters are tested by Analysis of Variance (ANOVA). A model equation is formed using coefficients obtained from Analysis of Variance (ANOVA) and this equation is used to find out optimum process parameters using Genetic Algorithms.

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