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Design and modeling of abrasive flow finishing of freeform surfaces of FDM printed femoral component of knee implant pattern

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Abstract

The design and manufacture of medical implants is a dynamic and important area of research, both from a medical and an engineering standpoint. For use in the actual fabrication of the end-use implant utilizing the investment casting method, a replica of a knee implant can be produced using the fused deposition modeling (FDM) technique. Whereas there are numerous benefits of the FDM process, the outer surface of the FDM printed parts are subjected to poor surface finishing due to the successive addition of material layers. So FDM printed details need to be post-processed using suitable surface finishing techniques, i.e., abrasive flow machining (AFM) process. This paper describes an experimental investigation on AFM of freeform surfaces of FDM printed femoral component of knee implant replica for investment casting application. The AFM media is made with a base material of corn-starch powder, a carrier medium of EDM oil, and additives of aloe barbadensis miller (aloe vera gel) and glycerin. The rheology of this newly developed AFM media has been measured and optimized for maximum material removal rate. AFM media is also characterized to check its thermal stability and functional elements using thermogravimetric analysis (TGA) and Fourier Transform Infrared (FTIR) spectroscopic method. Finally, the FDM printed pattern of the femoral component of the knee implant is finished using a one-way AFM machine using the newly prepared optimized AFM media. For an FDM printed pattern of a femoral component of a knee implant, the maximum percentage improvement in average surface roughness (Ra) that a medium based on corn-starch (50% corn-starch powder) can achieve is 83%, and the initial surface roughness was reduced by 81.58%, from 9.30 to 02.10 μm.

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Abbreviations

2D:

Two dimensional

3-D:

Three dimensional

3DP:

3-D printing

ABS:

Acrylonitrile butadiene styrene

AFM:

Abrasive flow machine

AM:

Additive manufacturing

ASTM:

American society for testing and materials

CAD:

Computer-aided design

CT:

Computed tomography

CNC:

Computer numerical control

CFD:

Computational fluid dynamics

DED:

Direct energy deposition

CSAM:

Cold spray additive manufacturing

DEM:

Discrete element method

DFAM:

Design for additive manufacturing

DLP:

Digital light processing

DMLS:

Direct metal laser sintering

EBAM:

Electron-beam additive manufacturing

EBM:

Electron beam melting

EDM:

Electric discharge machining

FDM:

Fused deposition modelling

FFF:

Fused filament fabrication

FTIR:

Fourier transform infrared

IC:

Investment casting

MDS:

Molecular dynamic simulation

MEX:

Material extrusion

MAF:

Magnetic abrasive finishing

MRF:

Magnetorheological finishing

MFP:

Magnetic float polishing

PLA:

Polylactic acid

RP:

Rapid prototyping

R-MRAFF:

Rotational-magnetorheological abrasive flow finishing

SLA:

Stereolithography

SLM:

Selective laser melting

SLS:

Selective laser sintering

SSE:

Stair-stepping effect

STL:

Standard triangle language

TGA:

Thermogravimetric analysis

WAAM:

Wire arc additive manufacturing

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Acknowledgements

The authors would like to thank the Science and Engineering Research Board, Department of Science and Technology, Government of India, for supporting this work through the grant DST-SERB EMR/2016/003372. Authors are also thankful to the material research center (MRC) at Malaviya National Institute of Technology (MNIT), Jaipur (Rajasthan), India, for providing me with AFM media characterization facilities, such as FTIR and TGA, to assess the success of my Ph.D. research.

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Authors and Affiliations

  1. Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur, 302017, India

    Abdul Wahab Hashmi, Harlal Singh Mali & Anoj Meena

  2. Department of Mechanical Engineering, GLA University, Mathura, UP, 28140, India

    Kuldeep K. Saxena

  3. Department of Mechanical Engineering and Industrial Design, University of Cadiz, Cadiz, Spain

    Ana Pilar Valerga Puerta

  4. Department of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India

    U. Sathish Rao

  5. Division of Research & Innovation, Uttaranchal University, Dehradun, Uttarakhand, 248007, India

    Dharam Buddhi

  6. Department of Medical Physics, Hilla University College, Babylon, Iraq

    Kahtan A. Mohammed

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  1. Abdul Wahab Hashmi
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Hashmi, A.W., Mali, H.S., Meena, A. et al. Design and modeling of abrasive flow finishing of freeform surfaces of FDM printed femoral component of knee implant pattern. Int J Interact Des Manuf 17, 2507–2526 (2023). https://doi.org/10.1007/s12008-022-01048-z

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