Numerical Impact of Tool Geometry on Hip Prosthesis Forming

This paper examines the effect of incremental forming parameters on the process of a 304L stainless-steel biomedical part, which is inserted between the prosthesis and the cup to minimize wear and extend the lifespan of the prosthesis. The methodology involves several steps. First, the tool trajectory is determined. Then, modeling and numerical simulation are performed to select the optimal configuration, evaluate the final product geometry and forming tool force in relation to the forming angle, define the forming tool dimensions, and determine the axial step. Finally, the evaluation of the spring-back is conducted, along with an analysis of the parameters that influence the thinning of the component. The results highlight the relationship between punch diameter and axial displacement on the geometric quality of the deformed component. Furthermore, the force exerted varies as a function of axial steps, forming tool geometry, and the dimensions of the deformed component. Additionally, the number of contact points and the forming angle have an impact on the thinning.