Virtual Machining of Total Knee Replacement Products Based on Finite Element Analysis (FEA) and Re-Design Optimization by ISO 14243

Abstract This study evaluates the performance of total knee replacement (TKR) components by examining the design, simulation, and machining processes involved. The purpose was to assess the suitability of computer-aided design (CAD) about established standards for total knee replacement (TKR) components, focusing on the femoral and tibial components. Finite element analysis (FEA) was conducted using Abaqus software to simulate stress and contact pressure on the components, specifically under ISO 14243-3 Standard loading conditions. The results revealed that stress concentrations and maximum contact pressure occurred at several points, with peak pressure observed on the lateral side of the femoral component. Based on these findings, the study included a redesign of the knee implant components, followed by re-validation using finite element analysis (FEA). The study also explored the machining process of the femoral component, highlighting the importance of using computer-aided manufacturing (CAM) software to ensure precision in producing complex geometries. CAM software simulations were used to verify tool paths and prevent manufacturing errors. These results underscore the importance of integrating CAD, FEA, and CAM processes to improve the design and production of TKR components.