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Hindawi

Modelling and Simulation in Engineering


Volume 2020, Article ID 4752479, 10 pages
https://doi.org/10.1155/2020/4752479

Research Article
Fatigue Characteristics and Numerical Modelling Prosthetic for
Chopart Amputation

Saif M. Abbas and Ammar I. Kubba


Prosthetics and Orthotics Engineering Department, College of Engineering, Al-Nahrain University, Baghdad, Iraq

Correspondence should be addressed to Ammar I. Kubba; [email protected]

Received 24 January 2020; Revised 20 September 2020; Accepted 22 October 2020; Published 16 November 2020

Academic Editor: Parviz Ghadimi

Copyright © 2020 Saif M. Abbas and Ammar I. Kubba. This is an open access article distributed under the Creative Commons
Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work
is properly cited.

This research is looking for three laminated composite material groups. These three groups were utilized in experimental
investigation to find their mechanical properties. These properties have been used to design and manufacture a socket for a
partial foot prosthesis using an ANSYS model. This socket was manufactured with a vacuum pressure device to improve its
properties. The socket composite material was tested for tensile and fatigue properties; then, its results were used in the ANSYS
model. The composite material matrix was laminated in an 80 : 20 ratio, and there were three types of reinforcement lamination
material (Perlon, glass fiber, and carbon fiber). The mechanical property results of these tests were found as follows: using only-
Perlon reinforcement, the properties are σy = 33:6 MPa, σult = 35:6 MPa, and modulus of elasticity = 1:03 GPa; using (3Perlon
+2carbon fiber +3perlon) layers, the properties were σy = 65:5 MPa, σult = 92:5 MPa, and modulus of elasticity = 1:99 GPa; and
using (3Perlon + 2 glass fiber + 3perlon) layers, the results were σy = 40 MPa, σult = 46:6 MPa, and modulus of elasticity = 1:4
GPa. The ANSYS model used the boundary condition from the measured contact pressure between the socket and the patient’s
stump. The MatScan (F-socket) pressure sensor utilized these interface pressure measurements. The maximum values for the
pressure were found as follows: 190 kPa and 164 kPa, which are recorded in the posterior and lateral locations, respectively. The
calculated factor of safety for the prosthesis that has been made from a selected composite material with the following layers (3
Perlon+2 carbon fiber+3 Perlon) is 1.037 which is safe for design prosthetic applications. From this study, more prosthetic
designs can be modelled and manufactured using this approach. Prosthetics and orthotics are usually custom-made for each
patient according to its specific requirements. So, it will be very helpful to find a procedure to analyze the prosthetics before
manufacturing it.

1. Introduction suitable gait pattern which can allow the patient to perform
normal activities. Then, the prosthesis appearance should
Partial foot amputation is a foot amputation between the be cosmetically acceptable. There are a wide range of partial
ankle joint and the lower distal limb. Prostheses for partial foot amputation prostheses which can be simple as bunched
foot amputations vary in design and function. Partial foot up socks or foam toe fillers. They also can be a sculptured
amputation is a type of amputation, which has many chal- Plastazote, elastomers2, or orthoprosthesis which can have
lenges for the rehabilitation physicians, the prosthesis techni- some extension that reaches to the patella tendon-bearing
cians, and the patient himself in comparison to other types of area [1]. As shown in Figure 1, the patient condition with a
amputations due to the complexity of this type of amputa- foot amputation has different names, such as transmetatarsal
tion. The structure of the partial foot prosthesis should be amputation, Chopart amputation, Lisfranc amputation,
strong to protect the amputation edges from the impact at Syme’s amputation, and ankle disarticulation. From these
heel strike and toe off, which should also be able to control names, the amputation position through the foot can be
the foot deformation in dorsiflexion, plantar flexion, ever- located; some of these names are from the surgeons who
sion, and inversion. Also, the prosthesis should simulate a deliver these amputations for the first time such as Chopart,
2 Modelling and Simulation in Engineering

Chopart

Figure 1: The Chopart amputation [7].

Lisfranc, and Syme. Partial foot amputation (PFA) is defined


as losing a part from the foot, either the forefoot or the hind-
foot [2], and it is typically due to diabetes [3–5]. Also, frost- Figure 2: Prosthetic and orthotic materials.
bite trauma and congenital anomalies can be another
example for other reasons for amputation [6]. During the
19th century, François Chopart was employed at a charitable
select the best option among them to make a socket with the
hospital in Paris, and he defined the disarticulation through
required performance. This study was utilized by finite ele-
the midtarsal joint [7]. At that time, this operation was
ment analysis using ANSYS (14.5) to determine the fatigue
thought to be having very limited applications due to the fact
safety factor numerally.
that the remaining of the foot is going to progress to equino-
The experimental and numerical data used to support the
varus deformity. As time passed, more people are in favour of
findings of this study are included within the article.
Chopart amputation because of its ability to keep the limbs’
total length and the high percentage of success during this
procedure. An improved high-topped shoe was introduced
to assist patients with apropulsive ambulation due to the
2. Experimental Procedures
combination of ankle fusion and hindfoot amputation [8–
11]. Jweeg et al. [12] used different layers of Perlon. Abbas The materials for Chopart amputation prostheses used in this
et al. [13] worked on a composite material of carbon fiber study are cotton Perlon, carbon and glass fibers, and resin
with Perlon and Perlon only. Research to investigate KAFO (80 : 20) with a hardener [23] as shown in Figure 2.
made with a carbon fiber material was performed by The tools and devices used for this research are listed as
Takhakh and Abbas [14]. follows:
Abbas investigates the effects of composite material
(1) A 10 ∗ 15 ∗ 25 cm mould from Jepson
layers on the prosthetic mechanical properties for partial foot
amputation [15]. Abbas et al. investigate the mechanical (2) Pressure vacuum to prevent gaps between the fiber
properties of a prosthesis designed for partial foot amputa- and the resin
tion [16]. Takhakh et al. studied the different types of com-
posite material lamination layers for prosthetic applications (3) Tensile test machine
[17]. S. M. Abbas and M. H. Abbas used carbon fiber with (4) Fatigue test for a flat specimen suitable for the com-
four layers to make a composite material for an above-the- posite material
knee amputation socket [18]. Salman et al. studied a compos-
ite material with a wide range of fiber reinforcements [19]. Three samples were tested for each type of composite
Also, Mostafa et al., Sharba et al., and Salman et al. investigate material in the tensile test device. These samples were pre-
the hybrid composite material and found its mechanical pared according to ASTM D638 type I [24] as shown in
properties with biaxial tensile, compression, and fatigue tests Figure 3(a). However, its thickness varies due to the type of
[20–22]. lay-up.
The aim of this work is to design and manufacture a pros- Ten samples for each group combination were utilized
thesis for Chopart amputation. This prosthesis is using one of for the fatigue test. The samples are shown in Figure 3(b);
the three composite material groups. The selected composite these samples are made according to the standard of the
material is processed by simulating the prosthetic model for fatigue device while thickness of the samples varies with each
these three groups using the mechanical properties collected group.
from the tests that were utilized in this study. The aim of the The following steps are measuring the partial foot ampu-
study was achieved by the following phases. tation socket dimensions for the patient to manufacture a
In the beginning, three types of lamination samples were socket. After manufacturing, the alignment of the partial foot
tested in tensile and fatigue tests, and they are 3 Perlon-2 car- prosthesis was done using the alignment tools to be ready to
bon fiber-3 Perlon, 3 Perlon-2 glass fiber-3 Perlon, and 6 Per- use by the patient.
lon with a matrix of lamination (80 : 20) resin. Then, a study The procedure to manufacture a socket can be listed in
of the mechanical properties for these materials was done to the following steps:
Modelling and Simulation in Engineering 3

ASTMD-638-I
R76 57 4 mm
D=4
19~
13 100 10
165~

(a) (b)

Figure 3: (a) The dimensions of the tensile specimen [24]. (b) The shape of the fatigue specimen [24].

A: Static Structural
Pressure
Time: 1. s
08/02/2019 01:55𝜌 B
A Fixed Support
B Pressure: 0.19 MPa

0.00 20.00 (mm) Z


10.00
Y

Figure 6: Prosthetic displacement condition and applied forces.


Figure 4: Patient with a MatScan sensor.

Geometry
08/02/2019 01:52𝜌

0.00 20.00 (mm) Z 0.00 20.00 (mm) Z


10.00
10.00
Y Y

Figure 5: Prosthesis geometry model. Figure 7: Prosthetic model elements.

(d) The normal foot’s length


(1) Measuring the following parameters from the
patient: (e) The patient shoe’s heel height

(a) The circumferences of the stump (2) Handing casting


(b) Mediolateral diameter at the calcaneus and malleolus (3) Preparing for rectification and cast rectification
(c) The amputee’s length (4) Soft socket manufacturing
4 Modelling and Simulation in Engineering

Table 1: The groups of lamination. Pressure vs. time


150
Thickness
No. Layers Definition of laminations

Pressure (kPa)
(mm) 100
Group 3 Perlon-2 carbon fiber-3
8 3.8
A Perlon
50
Group
8 3.8 3 Perlon-2 glass fiber-3 Perlon
B
0
Group 0 2 4 6 8 10 12 14 16 18 20 22
6 2.5 Perlon layers
C Time (seconds)

Table 2: Mechanical properties for each group.

Total no. of Thickness σy σult E


Laminations
layers (mm) (MPa) (MPa) (GPa)
Group A 8 3.8 65.5 92.5 1.99
Group B 8 3.8 40 46.6 1.4
Group C 6 2.5 33.6 35.6 1.03

100

80
Stress (MPa)

60
Figure 10: Pressure with time at the anterior region.
40

20
Pressure vs. time
0
0 2 4 6 8 10 150
Pressure (kPa)

Strain (%)
100
3p2c3p
3p2f3p 50
6p
0
–2 3 8 13 18
Figure 8: Tensile test curve for each group. Time (seconds)

120
100
Stress (MPa)

80
60
40
20
0
0 500000 1000000
No. of cycles to failure

3p2c3p
3p2f3p
6p Figure 11: Pressure with time at the lateral region.

Figure 9: S-N curves for each lamination.


(age (55 years), height (190 cm), and weight (88 kg)). The
(5) Adding lamination for the socket patient suffered from left foot amputation (Chopart ampu-
(6) Trimming and then finishing tation) due to an explosion. The interface pressure was
taken by using a sensor type (MatScan), shown in
Measure the interface pressure using an F-socket at dif- Figure 4, which can be used for this type of dynamic load
ferent regions of the patient who wears a prosthetic type PF applications.
Modelling and Simulation in Engineering 5

Pressure vs. time sis geometry was measured and modelled in ANSYS software
200 as shown in Figure 5. This model used the collected mechan-
ical properties from the tests of the three groups of the com-
Pressure (kPa)

150
posite material, which were used to make the socket. The
100 mechanical properties of the three different groups were used
to evaluate the stresses that were generated in the prosthetics
50
due to the weight and walking loading.
0 The prosthesis displacement boundary conditions and
0 2 4 6 8 10 12 14 16 18 the applied forces are shown in Figure 6.
Time (seconds) The software analyzes the prosthesis by creating elements
and nodes as shown in Figure 7.
The boundary conditions for this model can be classified
into displacement and applied force or pressure. The dis-
placement boundary conditions are in the bottom of the foot
where the foot is in contact with the ground. On the other
hand, the force and pressure applied to the prosthetic model
are from the weight of the patient (88 kg) and from the mea-
sured interface pressure from the MatScan sensor. The model
shows how the prosthesis will respond to the applied bound-
ary conditions above after solving this model.

4. Results and Discussion


4.1. Tensile Test Results. The specification of the three com-
Figure 12: Pressure with time at the posterior region. posite lamination layer groups is in Table 1.
The mechanical properties for these three lamination
layer groups are listed in Table 2. The stress-strain curve
Pressure vs. time for each lamination group is shown in Figure 8. These results
200 were collected from the tensile test data for this study.
The found data conclude that the yield strength σy of
Pressure (kPa)

150
group B has increased by 16% when two layers of glass fiber
100 were added to the lamination in group C; also, the ultimate
tensile strength σult has increased by about 24% and E by
50 26%. When comparing the results from groups A and C, it
was revealed that using two more layers of carbon fiber can
0
0 2 4 6 8 10 12 14 16 18 increase σy by 47%, σult by 62%, and E by 48%. The increase
Time (seconds) in these mechanical properties in groups A and B is due to
the mechanical properties of the glass fibers and the carbon
fibers added which are higher than that of Perlon.
(P) 130 kPa

4.2. Fatigue Property Results. The fatigue tests were utilized


for the three lamination groups in this research. The fatigue
tests were done using an alternative bending testing machine
with the specimen shown in Figure 3(b). The results from the
fatigue testing equipment show the specimens’ fracture test-
ing stress with a total number of cycles when the fracture
happened as shown in Figure 9.
Results in Figure 9 show that the amount of cycles in
fatigue failure is increasing with decreasing fatigue failure
stress. All the tests were conducted at room temperature.
Each test was repeated three times, and the results shown in
Figure 9 are the average for these data.
Figure 13: Pressure with time at the medial region. The collected data from the tensile and fatigue tests are
used in modelling the ANSYS finite element model to com-
pare its results.
3. Numerical Analysis
4.3. Interface Pressure Result. The contact or interface pres-
In this research, a finite element method was used to evaluate sure between the socket and the patient’s stump was
the fatigue characteristics of the prosthetic part. The prosthe- measured with a MatScan sensor as shown in Figure 4. The
6 Modelling and Simulation in Engineering

Table 3: Interface or contact pressure distribution between the socket and the patient’s stump.

Socket area or regions Anterior Lateral Posterior Medial


Interface or contact pressure (kPa) 108 164 190 130

A: Static Structural
Safety Factor
Type: Safety Factor
15 Max
Time: 0
08/02/2019 01:57𝜌

10

1.037 Min

0
0.00 20.00 (mm) Z
10.00
Y

Figure 14: Group A fatigue factor of safety.

A: Static Structural
Safety Factor 15 Max
Type: Safety Factor
Time: 0
08/02/2019 02:26𝜌
10

0.66545 Min

0
0.00 20.00 (mm) Z
10.00
Y

Figure 15: Group B fatigue factor of safety.

sensor was located on the anterior, posterior, lateral, and 4.4. Numerical Results. The analysis of the partial foot type
medial regions, and their results are shown in Figures 10– Chopart prosthetic model was analyzed by finite element
13. In Table 3, the maximum pressure values of the socket using computer ANSYS software, which can find the total
and its position are listed. The higher pressure value was deformation, resultant stress (von Mises stress), and fatigue
recorded at the posterior area with 190 kPa, and the pressure safety factor.
value at the lateral area is 164 kPa. This pressure distribution The data show the factor of safety for the three types
in the posterior and lateral muscles is due to the extra activity of the partial foot prosthetic model, which are presented
in these muscles during walking to avoid extra pressure in the in Figures 14–16, respectively. The von Mises stress
area of tibia bone (medial region and anterior region). This results of the prosthetic three groups are shown in
type of contact pressure distribution is very common with Figures 17–19. The total deformation is shown in
patients having this type of amputation. Figures 20–22 which are for the three groups of the lam-
The collected data from the interface contact pressure are ination composites.
used as the boundary condition to solve the ANSYS finite ele- The factor of safety for group A is 1.037 which is accept-
ment model. able for this type of applications.
Modelling and Simulation in Engineering 7

A: Static Structural
Safety Factor 15 Max
Type: Safety Factor
Time: 0
08/02/2019 02:31𝜌 10

0.22625 Min

0
0.00 20.00 (mm) Z
10.00
Y

Figure 16: Group C fatigue factor of safety.

A: Static Structural
Equivalent Stress 53.038 Max
Type: Equivalent (von-Mises) Stress
Unit: MPa 47.147
Time: 1
08/02/2019 01:58𝜌
41.255

35.364

29.473

23.581

17.69

11.799

5.9075

0.016184 Min
0.00 20.00 (mm) Z
10.00
Y

Figure 17: Equivalent stress (von Mises) in group A.

A: Static Structural
Equivalent Stress
22.541 Max
Type: Equivalent (von-Mises) Stress
Unit: MPa 20.037
Time: 1
08/02/2019 02:26𝜌
17.534

15.03

12.526

10.022

7.5183

5.0145

2.5107

0.0068782 Min

0.00 20.00 (mm) Z


10.00
Y

Figure 18: Equivalent stress (von Mises) in group B.


8 Modelling and Simulation in Engineering

A: Static Structural
Equivalent Stress
Type: Equivalent (von-Mises) Stress 66.297 Max
Unit: MPa
58.933
Time: 1
08/02/2019 02:31𝜌
51.569

44.205

36.841

29.477

22.113

14.748

7.3844

0.02023 Min

0.00 20.00 (mm) Z


10.00
Y

Figure 19: Equivalent stress (von Mises) in group C.

A: Static Structural
Total Deformation 1.1386 Max
Type: Total Deformation
Unit: mm 1.0121
Time: 1
08/02/2019 02:26𝜌 0.88555

0.75904

0.63253

0.50603

0.37952

0.25301

0.12651

0 Min
0.00 20.00 (mm) Z
10.00
Y

Figure 20: The total deformation in group A.

A: Static Structural
Total Deformation 1.8781 Max
Type: Total Deformation
Unit: mm 1.6694
Time: 1
08/02/2019 01:58𝜌 1.4607

1.2521

1.0434

0.83471

0.62603

0.41735

0.20868

0 Min
0.00 20.00 (mm) Z
10.00
Y

Figure 21: The total deformation in group B.


Modelling and Simulation in Engineering 9

A: Static Structural
Total Deformation 3.3487 Max
Type: Total Deformation
Unit: mm 2.9766
Time: 1
08/02/2019 02:32𝜌 2.6046

2.2325

1.8604

1.4883

1.1162

0.74416

0.37208

0 Min

0.00 20.00 (mm) Z


10.00
Y

Figure 22: The total deformation in group C.

5. Conclusions Conflicts of Interest


(1) The material selection procedure for the prosthesis The authors declare that they have no conflicts of interest.
used in this research can be used in a wide range of
prosthetics and orthotics, as most of these applications
are custom-made for each patient due to the special Acknowledgments
amputation specifications, body dimensions, patient’s
weight, and other factors. So, by modelling the pro- This research was supported by the College of Engineering,
posed prosthesis, it can find what material is the best Al-Nahrain University.
for the patient’s requirements from the total deflection
to the factor of safety from the model results
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