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Journal of Mechanical Engineering Research and Developments ISSN: 1024-1752 CODEN: JERDFO Vol. 43, No. 5, pp. 384-399 Published Year 2020 384 Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing Ehab N. Abbas , Muhsin J. Jweeg , Muhannad Al-Waily ‡†* Ministry of Higher Education and Scientific Research, Studies & Planning & Follow-Up Directorate, Iraq Al-Farahidi University, College of Technical Engineering, Iraq ‡† Department of Mechanical Engineering, Faculty of Engineering, University of Kufa, Iraq *Corresponding Author Email: [email protected] ABSTRACT: The below knee Prostheses sockets are subjected to varying loading conditions during the gait cycle. This will cause a fatigue in the sockets due to the induced tension and compression stresses developed during the gait cycle. Recently, the using of the laminated composites are widely used in the rehabilitation centers. The engineer should be based his design on the endurance stress level instead of the allowable stresses which are higher than the endurance level. The Prosthesis engineer should be given these levels of stresses for safe and durable product and cheap at the same time. In this work, five types of stacking sequence were chosen based upon a previous work of the authors. These are arranged (4 perlon+4 glass+ 4 perlon), (4 perlon+4 carbon+4 perlon) and three mixed samples (3perlon+2 kevlar+2 perlon+2 carbon+3 perlon), (3 perlon+2 kevlar+2 perlon+2 carbon+3 perlon), and (3 perlon+2 kevlar+2 perlon+3 carbon+2 perlon). The matrix which has been proved effective is the Ortocryl. A comprehensive program of fatigue experiments were achieved to predict the suitable type of laminate for the socket prostheses manufacturing which can sustain the dynamic fatigue during the gait cycle in addition to the finite element modeling. The experimental results have a good agreement with those obtained using the Finite Element Method with a maximum discrepancy not exceed 12%. It was found that the sample No. 2 has the maximum decay factor = −2.706 with a maximum number of cycles up to failure = 21.35 × 10 5 cycle for the constant amplitude test and the damage factor in the variable amplitude test is increased with the increasing the number of cycles at each test. The obtained results indicate that they can be used or manufacturing the socket prostheses depending upon the required sustainability, age of the patient and the daily work type. KEYWORDS: Fatigue, composites, amplitude stress, Sockets, prostheses. INTRODUCTION The laminated composite materials are widely used in socket prostheses manufacturing in rehabilitation centers of people of special needs. The reason behind it is the high strength/weight ratio, comfort and reliable to be used in this respect. The amputees may suffer a dynamic loading through the gait cycle. Recently, this subject was deeply studied by many researchers [1-5]. The fatigue is considered one of the main sources of failure of the sockets which create unreliable wearing and causes a socket failure in addition to the cost required to be replaced. M.J. Jweeg et al. [6] carried out an experimental investigation of the fatigue of fiber glass with polyster resin taking into consideration the reversal bending loading. The results have shown that the composites fail under different damages due to the delamination caused by shear and fatigue loading. K.R. Al-Rawi et al. [7] dealt with the fatigue of three layers glass and Kevlar woven roving [00 900] using the epoxy matrix. They concluded that the reinforcement has increased the fatigue strength of the composites. The side of the glass fibers has shown a more fatigue strength compared to the Kevlar side. A.M.A. Al-Nassrawi [8] investigated the characterization of fatigue behavior of PEEK matrix composites and studying the effects of notched created due to fatigue and their effects on fatigue strength of materials taking into consideration the temperature effects. The research was conducted experimentally and numerically using the finite element technique. A.A. Al-Assadi [9] entered the effects of high-low and low-high cycle fatigue on rubber materials in addition to the constant amplitude tests. He derived the life of the rubber materials formula for prediction the number of cycles up to failure and concluded that the variable amplitude testing is important in defining the rubber life and

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  • Journal of Mechanical Engineering Research and Developments ISSN: 1024-1752

    CODEN: JERDFO

    Vol. 43, No. 5, pp. 384-399

    Published Year 2020

    384

    Fatigue Characterization of Laminated Composites used in

    Prosthetic Sockets Manufacturing

    Ehab N. Abbas†, Muhsin J. Jweeg‡, Muhannad Al-Waily‡†*

    †Ministry of Higher Education and Scientific Research, Studies & Planning & Follow-Up Directorate, Iraq ‡Al-Farahidi University, College of Technical Engineering, Iraq

    ‡†Department of Mechanical Engineering, Faculty of Engineering, University of Kufa, Iraq

    *Corresponding Author Email: [email protected]

    ABSTRACT: The below knee Prostheses sockets are subjected to varying loading conditions during the gait cycle.

    This will cause a fatigue in the sockets due to the induced tension and compression stresses developed during the

    gait cycle. Recently, the using of the laminated composites are widely used in the rehabilitation centers. The

    engineer should be based his design on the endurance stress level instead of the allowable stresses which are

    higher than the endurance level. The Prosthesis engineer should be given these levels of stresses for safe and

    durable product and cheap at the same time. In this work, five types of stacking sequence were chosen based upon

    a previous work of the authors. These are arranged (4 perlon+4 glass+ 4 perlon), (4 perlon+4 carbon+4 perlon)

    and three mixed samples (3perlon+2 kevlar+2 perlon+2 carbon+3 perlon), (3 perlon+2 kevlar+2 perlon+2

    carbon+3 perlon), and (3 perlon+2 kevlar+2 perlon+3 carbon+2 perlon). The matrix which has been proved

    effective is the Ortocryl. A comprehensive program of fatigue experiments were achieved to predict the suitable

    type of laminate for the socket prostheses manufacturing which can sustain the dynamic fatigue during the gait

    cycle in addition to the finite element modeling. The experimental results have a good agreement with those

    obtained using the Finite Element Method with a maximum discrepancy not exceed 12%. It was found that the

    sample No. 2 has the maximum decay factor = −2.706 with a maximum number of cycles up to failure =

    21.35 × 105 cycle for the constant amplitude test and the damage factor in the variable amplitude test is increased

    with the increasing the number of cycles at each test. The obtained results indicate that they can be used or

    manufacturing the socket prostheses depending upon the required sustainability, age of the patient and the daily

    work type.

    KEYWORDS: Fatigue, composites, amplitude stress, Sockets, prostheses.

    INTRODUCTION

    The laminated composite materials are widely used in socket prostheses manufacturing in rehabilitation centers

    of people of special needs. The reason behind it is the high strength/weight ratio, comfort and reliable to be used

    in this respect. The amputees may suffer a dynamic loading through the gait cycle. Recently, this subject was

    deeply studied by many researchers [1-5]. The fatigue is considered one of the main sources of failure of the

    sockets which create unreliable wearing and causes a socket failure in addition to the cost required to be replaced.

    M.J. Jweeg et al. [6] carried out an experimental investigation of the fatigue of fiber glass with polyster resin

    taking into consideration the reversal bending loading. The results have shown that the composites fail under

    different damages due to the delamination caused by shear and fatigue loading. K.R. Al-Rawi et al. [7] dealt with

    the fatigue of three layers glass and Kevlar woven roving [00 – 900] using the epoxy matrix. They concluded that

    the reinforcement has increased the fatigue strength of the composites. The side of the glass fibers has shown a

    more fatigue strength compared to the Kevlar side. A.M.A. Al-Nassrawi [8] investigated the characterization of

    fatigue behavior of PEEK matrix composites and studying the effects of notched created due to fatigue and their

    effects on fatigue strength of materials taking into consideration the temperature effects. The research was

    conducted experimentally and numerically using the finite element technique.

    A.A. Al-Assadi [9] entered the effects of high-low and low-high cycle fatigue on rubber materials in addition to

    the constant amplitude tests. He derived the life of the rubber materials formula for prediction the number of

    cycles up to failure and concluded that the variable amplitude testing is important in defining the rubber life and

  • 385

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    should be considered. E.K. Gamstedt et al. [10] investigated the fatigue behavior of glass fibers reinforced

    polypropylene. The results indicated that the young’s modulus degrades for materials glass fibers/polypropylene

    due to fatigue effects. W. Hawang and K.S. Han [11] investigated the cumulative damage due to fatigue high-low

    and low-high cycle fatigue and suggested three models which are fatigue mode I and the resultant strain modes II

    and III. They concluded that the stress resultant could be employed to define cumulative damage models and the

    fatigue damage can be predicted with the stress – number of cycles curve (S-N). The also reached to conclusion

    that the cumulative damage model can give an explanation to the multi stress state and the number of cycles up

    to failure.

    L.M. Andre et al. [12] studied the fatigue damage loading due flexion and the effects of stress amplitude on the

    accumulative damage at room temperature. They compared their results with Minor’s fatigue life. They concluded

    that the damage factor may be more than unity. H. Mao and S. Mahadevan [13] conducted a work related to the

    fatigue of composite materials and the mechanisms of the induced damage . They proposed a mathematical model

    based upon the experimental results. They concluded that the growth of the damage passes through stages, stage

    I, the damage grows rapidly due to multi types of damages, stage II, the damage grows steadily and the third stage

    III. The damage again grows fast due to the fibre fracture which reduces the fatigue strength. W.V. Paepegem and

    J. Degrieck, [14] investigated the fatigue characteristics of plain woven glass/epoxy. An experimental program

    and a numerical solution were employed in this work. The samples [# 00 ] and [# 450 ] were prepared using the

    bending fatigue experiments. It was found that there is a degradation of the stiffness due to fatigue effects. They

    reached to a useful model for the composite materials fatigue characterization.

    This work aims to refill the research gaps in the fatigue characterization of laminates used for the prostheses socket

    manufacturing for people of special needs. It is an extension of a previous work for the authors [15] related to a

    mechanical properties finding specially used in rehabilitation centers to modify their life and durability and

    reliability of these types of structures in which the fatigue is not well understood yet.

    FINITE ELEMENT MODELING

    The finite element technique was used to calculate the fatigue behavior for composite laminate materials, [16-21].

    These, the behavior calculated included evaluated the stress-number of cycle relation for composite materials. In

    addition, the numerical results evaluated comparison with experimental results will calculating, [22-27]. There,

    the Ansys 14 software was used using the general procedure and defining the geometry and material properties,

    [28-31]. The modulus of elasticity, poison’s ratio, ultimate stress, amplitude stress, will be calculated in the

    experimental work, [32-36]. In addition to the support conditions and the loading causing the cyclic behavior of

    the sample in order to obtain the numerical S-N curve, [37-40]. The model to be tested experimentally is drawn

    by using solid work software as shown in Fig. 1, and supported as shown in Fig. 2. The solid 45 brick element 8

    nodes was used for modeling the tested sheets, as shown in Fig. 3. The total number of nodes is (1148522) and

    the total number of elements is (269110) required for the solution convergence, according to use mesh generation,

    [41-46], and the fatigue samples with its selected mesh given in Fig. 4.

    Figure 1. Fatigue sample dimensions.

  • 386

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    Figure 2. Fixed fatigue sample.

    Figure 3. Solid brick element.

    Figure 4. Mesh fatigue sample.

    THEORETICAL ANALYSIS

    In fatigue analysis, the stress amplitude is given by,

    σa =(σmax−σmin)

    2 (1)

    Where, σa, σmax, σmin are the stress amplitude, maximum stress and minimum stress for a complete fatigue cycle,

    as shown in Figure 5.

  • 387

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    Figure 5. Stress for a Complete Fatigue Cycle.

    The relation between the stress amplitude σa and the number of cycle Nf is given by, [6],

    σa = K. Nfm (2)

    Where, K and m are constants.

    They are found empirically based upon the experimental results according to Miner’s,

    ∑ni

    Nf

    ri=1 = D (3)

    Where, n is the number of cycles and D is the damage factor and r is the number of loading turns. Using the

    formula derived by,

    χi =Nf(σi−σL)

    (σH−σL) (4)

    Where, σH, σL are the maximum and minimum stresses for the variable amplitude stress and χ is the number of

    cycles up to failure under constant amplitude stress, σi and,

    D = (n

    Nf(σH)+

    n

    Nf(σL)) χ (5)

    EXPERIMENTAL PROGRAM AND RESULTS

    The work is concentrated on the types of laminates composite materials used in manufacturing the prostheses for

    people of special needs. They are chosen from previous work of the authors. The fatigue specimens were cut

    according to the machine fatigue sample, [47-53], as show in Figs. 6 and 7. The testing will be achieved for

    constant and variable amplitude in order to estimate the life of the material in order to be taken into consideration

    in designing the prostheses for the amputees, [54-60]. The types of the specimens and the stacking sequence are

    shown in Table 1, [15]. Ten specimens testing to calculate the fatigue behavior for samples, [61-66].

    Figure 6. Fatigue specimens.

  • 388

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    Figure 7. Fatigue test machine.

    Table 1. Fatigue test specimens.

    No. Laminate stacking sequence σult (MPa) E (GPa) G (GPa) ν

    1 (4) Perlon+(4) Glass Fiber+(4) Perlon 98.8 25.4 10.08 0.26

    2 (4) Perlon+(4) Carbon Fiber+(4) Perlon 124.7 25.6 10 0.28

    3 (3) Perlon+(2) Kevlar Fiber+(2)

    Perlon+(2) Glass Fiber+(3) Perlon 118.3 31.5 12.12 0.3

    4 (3) Perlon+(2) Carbon Fiber+(2)

    Perlon+(2) Glass Fiber+(3) Perlon 95.3 24.6 9.5 0.29

    5 (3) Perlon+(2) Kevlar Fiber+(2)

    Perlon+(2) Carbon Fiber+(3) Perlon 102.3 26.3 10.35 0.27

    The experimental results are divided into two types:

    1. Constant amplitude test.

    2. Variable amplitude test.

    For sample No. 1, the laminate is manufacture as shown in Table 1 and tested using the constant amplitude for

    each test. Ten specimens were decided from the previous work. The results of the constant amplitude used with

    the number of cycles up to failure is shown in Table 2. The amplitude versus the number of cycle is shown in

    Figure 8. In addition, the finite element results are added on the same figure.

    Table 2. Results of the constant amplitude for the laminate ((4) Perlon+(4) Glass Fiber+(4) Perlon).

    No. Constant amplitude (MPa) No. of cycles Nf

    1 25.8 4.3 × 105

    2 21.8 4.9 × 105

    3 15.6 5.31 × 105

    4 12.5 5.7 × 105

    5 9.6 7.2 × 105

    6 7.2 8.8 × 105

    7 4.8 10.35 × 105

    8 3.5 12.35 × 105

    9 2.4 15.4 × 105

    10 1.68 16.8 × 105

  • 389

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    Figure 8. Experimental and Numerical Results for Stress σa with Number of cycle Nf for the laminate No. 1.

    Using the curve fitting formula, the equation that fit the experimental results is, σa = K. Nfm, Where, K =

    1 × 1012, m = −1.897. The variable amplitude fatigue test by choosing two cases, Low-High and High-Low to

    show the effectiveness of the variable amplitude stress are shown in Table 3.

    Table 3. Vairable amplitude fatigue for the laminate ((4) Perlon+(4) Glass Fiber+(4) Perlon).

    No.

    Amplitude fatigue

    Low-High High-Low

    σa (MPa) Nf No. of Cycles. χ D σa (MPa) Nf No. of Cycles. χ D

    1 1.68 4.6 × 106 23 1.11 25.8 3.8 × 106 19 1.08

    2 5.7 4.8 × 106 24 1.12 19.4 4.01 × 106 20 1.13

    3 10.2 4.5 × 106 22 1.09 14.8 3.62 × 106 18 0.99

    4 14.8 3.98 × 106 20 1.03 10.2 3.3 × 106 17 0.97

    5 19.4 3.2 × 106 16 0.98 14.8 3.8 × 106 19 1.08

    6 25.8 4.23 × 106 21 1.07 1.68 3.92 × 106 20 1.12

    For sample No. 2, the stacking sequence together with the material properties are shown in Table 1. The results

    of the amplitude with the number of cycles are shown in Table 4 and the plots of the experimental and the

    numerical results are shown in Figure 9.

    Table 4. Results of constant amplitude for the laminate ((4) Perlon+(4) Carbon Fiber+(4) Perlon).

    No. Constant stress σa amplitude (MPa) No. of cycles Nf

    1 32.35 5.95 × 105

    2 25.84 6.42 × 105

    3 19.71 7.86 × 105

    4 17.47 8.23 × 105

    𝜎1 = 25.8 𝑀𝑃𝑎

    𝜎2 = 1.68 𝑀𝑃𝑎

    𝑛 = 104 𝑛 = 104

    𝜎2 = 1.68 𝑀𝑃𝑎

    𝑛 = 104

    𝜎1 = 25.8 𝑀𝑃𝑎

    𝑛⬚ = 104

  • 390

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    5 12.65 9.07 × 105

    6 8.4 11.26 × 105

    7 5.72 13.03 × 105

    8 3.5 15.62 × 105

    9 1.8 19.25 × 105

    10 0.504 21.35 × 105

    Figure 9. Experimental and Numerical Results for Stress σa with Number of cycle Nf for the laminate No. 2.

    Using the curve fitting formula, the equation that fit the experimental results is, σa = K. Nfm, Where, K =

    2 × 1017, m = −2.706. The variable stress amplitude σa for Low-High and High-Low are shown in Table 5.

    Table 5. Amplitude fatigue for the laminate ((4) Perlon+(4) Carbon Fiber+(4) Perlon).

    No.

    Amplitude fatigue

    Low-High High-Low

    σa (MPa) Nf No. of Cycles. χ D σa (MPa) Nf No. of Cycles. χ D

    1 0.504 6.82 × 105 35 1.05 32.35 5.62 × 105 29 1.03

    2 8.48 6.45 × 105 33 1.03 29.19 5.83 × 105 30 1.03

    3 15.10 5.98 × 105 29 0.97 21.93 4.98 × 105 24 0.96

    4 21.93 7.03 × 105 38 1.09 15.10 4.88 × 105 24 0.98

    5 29.19 6.92 × 105 36 1.08 8.48 5.23 × 105 26 0.99

    6 32.35 6.4 × 105 31 0.99 0.504 6.03 × 105 33 1.1

    For sample No. 3, laminate ((3) Perlon+(2) Kevlar Fiber+(2) Perlon+(2) Glass Fiber+(3) Perlon). The results of

    the constant amplitude is shown in Table 6. The σa amplitude values against the number of cycles are shown in

    Fig. 10 together with the numerical results.

    𝜎1 = 32.35 𝑀𝑃𝑎

    𝜎2 = 0. 504𝑀𝑃𝑎

    𝑛 = 104 𝑛 = 104

    𝜎2 = 0.504𝑀𝑃𝑎

    𝑛 = 104

    𝜎1 = 32.35 𝑀𝑃𝑎

    𝑛 = 104

  • 391

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    Table 6. Results of the constant amplitude fatigue test.

    No. Constant amplitude σa (MPa) No. of cycles Nf

    1 27.98 4.5 × 105

    2 21.72 5.38 × 105

    3 17.16 5.91 × 105

    4 12.64 6.61 × 105

    5 9.97 8.45 × 105

    6 6.35 10.3 × 105

    7 5.13 12 × 105

    8 4.67 14.33 × 105

    9 3.42 17.86 × 105

    10 2.33 19.48 × 105

    Figure 10. Experimental and Numerical Results for Stress σa with Number of cycle Nf for the laminate No. 3.

    The equation that describes the constant amplitude fatigue test is obtained by curve fitting as follows, σa = K. Nfm,

    Where, K = 3 × 1010, m = −1.595. The variable amplitude tests are, Low-High and High-Low fatigue test and

    the results are shown in Table 7.

    Table 7. Amplitude fatigue for the laminate No.3.

    No.

    Amplitude fatigue

    Low-High High-Low

    σa (MPa) Nf No. of Cycles. χ D σa (MPa) Nf No. of Cycles. χ D

    1 2.33 5.8 × 106 28 0.97 27.98 5.12 × 106 28 1.09

    2 5.1 5.64 × 106 27 0.96 21.41 4.83 × 106 23 0.96

    3 11.87 6.81 × 106 38 1.12 16.64 5.65 × 106 32 1.13

    4 16.64 6.4 × 106 32 1.00 11.87 5.2 × 106 29 1.11

    𝜎1 = 27.98 𝑀𝑃𝑎

    𝜎2 = 2.33 𝑀𝑃𝑎

    𝑛 = 104 𝑛 = 104

    𝜎2 = 27.98 𝑀𝑃𝑎

    𝑛 = 104

    𝜎1 = 2.33 𝑀𝑃𝑎

    𝑛 = 104

  • 392

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    5 21.41 6.93 × 106 39 1.12 5.1 4.98 × 106 24 0.96

    6 27.98 6.45 × 106 33 1.03 2.33 4.63 × 106 25 1.08

    For sample No. 4, the laminate is manufacture as shown in Table 1 and tested using the constant amplitude for

    each test. The results of the amplitude used with the number of cycles up to failure is shown in Table 8. The

    constant amplitude versus the number of cycle is shown in Fig. 11 together with the numerical results.

    Table 8. Results of the constant amplitude for the laminate No. 4.

    No. Constant amplitude (MPa) No. of cycles Nf

    1 24.8 5.95 × 105

    2 21.16 6.98 × 105

    3 18.52 7.32 × 105

    4 15.98 7.62 × 105

    5 12.98 8.82 × 105

    6 9.35 10.27 × 105

    7 6.98 11.98 × 105

    8 3.532 14.5 × 105

    9 2.4 17.87 × 105

    10 1.58 19.42 × 105

    Figure 11. Experimental and Numerical Results for Stress σa with Number of cycle Nf for the laminate No. 4.

    Using the curve fitting formula, the equation that fit the experimental results is, σa = K. Nfm, Where, K =

    8 × 1014, m = −2.327. The variable amplitude fatigue test by choosing two cases, low-high and high-low to

    show the effectiveness of the variable amplitude stress are shown in Table 9.

    Table 9. Amplitude fatigue for the laminate No. 4.

    No. Amplitude fatigue

    Low-High High-Low

  • 393

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    σa (MPa) Nf No. of Cycles. χ D σa (MPa) Nf No. of Cycles. χ D

    1 1.58 5.7 × 105 29 1.01 24.8 4.52 × 105 23 1.02

    2 4.38 5.35 × 105 27 1.02 19.68 4.73 × 105 25 1.06

    3 9.46 4.98 × 105 24 0.96 14.54 4.14 × 105 19 0.93

    4 14.54 6.01 × 105 34 1.13 9.46 4.2 × 105 19 0.9

    5 19.68 5.98 × 105 32 1.07 4.38 4.48 × 105 21 0.94

    6 24.8 5.3 × 105 25 0.94 1.58 5.32 × 105 30 1.13

    For sample No. 5, the laminate is manufacture as shown in Table 1 and tested using the constant amplitude for

    each test. The results of the amplitude used with the number of cycles up to failure is shown in Table 10. The

    constant amplitude versus the number of cycle is shown in Fig. 12. The numerical results were also plotted on the

    same figure.

    Table 10. Results of the constant amplitude for the laminate No. 5.

    No. Constant amplitude (MPa) No. of cycles Nf

    1 28.6 4.9 × 105

    2 25.82 5.62 × 105

    3 22.42 6.35 × 105

    4 19.63 7.3 × 105

    5 16.16 8.28 × 105

    6 13.48 9.35 × 105

    7 10.12 11.86 × 105

    8 7.06 14.34 × 105

    9 5.53 16.83 × 105

    10 3.48 17.35 × 105

    Figure 12. Experimental and Numerical Results for Stress σa with Number of cycle Nf for the laminate No. 5.

    𝜎1 = 4.98 𝑀𝑃𝑎

    𝜎2 = 0.24 𝑀𝑃𝑎

    𝑛⬚ = 104 𝑛 = 104

    𝜎2 = 0.24 𝑀𝑃𝑎

    𝑛 = 104

    𝜎1 = 4.98 𝑀𝑃𝑎

    𝑛 = 104

  • 394

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    Using the curve fitting formula, the equation that fit the experimental results is, σa = K. Nfm, Where, K =

    1 × 1010, m = −1.518. The variable amplitude fatigue test by choosing two cases, low-high and high-low to

    show the effectiveness of the variable amplitude stress are shown in Table 11.

    Table 11. Amplitude fatigue for the laminate No. 5.

    No.

    Amplitude fatigue

    Low-High High-Low

    σa (MPa) Nf No. of Cycles. χ D σa (MPa) Nf No. of Cycles. χ D

    1 3.48 6.2 × 105 34 1.09 28.6 3.92 × 105 21 1.08

    2 8.28 7.1 × 105 40 1.13 23.78 4.1 × 105 23 1.12

    3 13.01 5.2 × 105 27 1.04 18.92 4.6 × 105 27 1.14

    4 18.92 4.9 × 105 23 0.94 13.01 3.6 × 105 17 0.94

    5 23.78 3.2 × 105 16 0.93 8.28 3.4 × 105 15 0.88

    6 28.6 4.96 × 105 24 0.97 3.48 3.1 × 105 13 0.84

    DISCUSSION OF RESULTS

    The presented experimental and finite element technique to estimate the life of the materials to be used specifically

    for manufacturing the prosthetic sockets. This a part of the research work deals with the fatigue characterization

    to prostheses materials to sustain the dynamic loading facing the patient during the gait cycle. Five types of

    materials tested by E.N. Abbas et al. [15] were chosen for testing in this work. The materials were tested

    experimentally using two types of loading systems, constant amplitude and variable amplitude schemes in order

    to obtain results approximately similar to the real life results.

    The first set of specimens (4 layers of perlon + 4 layers of fiber glass and 4 perlon layers). The constant amplitude

    results are shown in Fig. 8 together with the finite element result. They have shown a good agreement with a

    discrepancy less than 12%. The suggested experimental model is shown on Fig. 8 with K = 1 × 1012 and m =

    −1.897. The minus sign indicates that the life is increased with the amplitude decreasing which is compatible

    with the logic of material behavior. The number of cycles to failure was 16.8*105 cycle. For using the variable

    amplitude stress shown in Table 3 indicates that the number of cycles to failure in case of Low- High cycle is

    higher than those obtained from High–Low regime with maximum numbers of cycles = 4.6 × 106, 3.8 × 106,

    respectively. The results for the damage indicates that the expected life is increasing with the increase the damage

    factor D obtained by using Eq. (2). This is illustrated in Table 3.

    The sample No. 2 is composed of (4 perlon layers + 4 carbon fiber layers + 4 perlon layers). The number of cycles

    obtained against the constant amplitude model results in K = 2 × 1017, m = −2.706 as shown in Fig. 9 and Table

    4 which has a similar behavior for the specimen No.1. Using the variable amplitude test, Table 5, it was found

    that the maximum number of cycles to failure is equal to 7.03 × 105 with a damage factor equal to 1.09 using

    Low–High scheme compared to 6.03 × 105 cycle in High–Low with a damage factor equal to 1.1. For the sample

    No. 3 in which the laminate is composed of Kevlar fibers in addition to fiber glass fibers, a noticeable number of

    cycles to failure is obtained as shown in Table 6 and Fig. 10. For constant amplitude test as shown in Table 7, the

    maximum number of cycles reached 19.48 × 105 cycle and in using the Low-High test the number of cycles to

    failure is equal to 6.93 × 106 with a damage factor D = 1.03 and in High–Low test the number of cycles to failure

    is equal to 5.102 × 106 with a damage factor D = 1.09. The index for the decay in the number of cycles in

    constant test indicate high rate (−2.327) and the corresponding number of cycles up to failure reaches

    𝜎1 = 28.6 𝑀𝑃𝑎

    𝜎2 = 3.48 𝑀𝑃𝑎

    𝑛 = 105 𝑛 = 105

    𝜎2 = 3.48 𝑀𝑃𝑎

    𝑛 = 105

    𝜎1 = 28.6 𝑀𝑃𝑎

    𝑛 = 105

  • 395

    Fatigue Characterization of Laminated Composites used in Prosthetic Sockets Manufacturing

    19.42 × 105 compared to the other samples which may be recommended for socket manufacturing.

    For the sample No. 4 in which the laminate is composed of carbon fibers in addition to kevlar fibers, the maximum

    number of cycles reached 19.42 × 105 cycle for a constant amplitude test shown in Table 8 and Fig. 11 and in

    using the Low-High test the number of cycles to failure is equal to 6.01 × 106 with a damage factor D = 1.13

    and in High–Low test the number of cycles to failure is equal to 5.3 × 106 with a damage factor D = 1.13 as

    shown in Table 9. For the laminate (specimen No. 5) (3 perlon + 2 kevlar + 2 perlon + 2 carbon + 3 perlon) layers

    the maximum number of cycles to failure for constant amplitude test is 17.35 × 105 as shown in Fig. 12 and

    Table 10. For the variable test amplitude as shown in Table 11, the maximum number of cycles to failure is

    7.1 × 105 with a damage factor D = 1.13, and 4.6 × 105 for a damage factor D = 1.14 for the tests respectively

    Low – High and High – Low tests respectively. The number of cycles to failure is used as an indication to the

    stiffness degradation. The fatigue failure causes initiation of cracks in the sockets prostheses due to the increasing

    the number of cycles beyond the fatigue strength for a typical laminate. The determination of the endurance of the

    laminate before manufacturing the sockets, therefore, this work is considered as a guide for the Prostheses

    engineers.

    CONCLUSION

    The research conducted here deals with the determination of the endurance limits for the materials used for

    manufacturing the prostheses sockets. The results may be used to avoid the failure of sockets and get rid of the

    stiffness degradation due to unexpected loading faces the patient during the gait cycle by using the models

    suggested in this work with the corresponding the number of cycles up to failure according to the age and the

    activity of the patient during the normal daily work. The results of the constant amplitude with the number of

    cycles for all the samples have a good agreement with those obtained numerically using the finite element method.

    It was noticed that using the variable stress amplitude Low - High, the number of cycles are higher than those

    obtained for the case High – Low. The damage factor was also increased as the number of cycles up to failure is

    increased.

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