Investigating of Manufacturing of Titanium Hip Prosthesis by Cold Forging Process via FEM Analysis

The forging process is a typical process to manufacture industrial parts that are subjected to fatigue stresses. The forged parts have equiaxial grains, and crack propagation occurs at a lower rate.  A part's mechanical properties stem from its manufacturing process and initial materials. One of the applications of the forging process is manufacturing different kinds of metallic prostheses such as hip prostheses, which are very privileged in medical and rehabilitating issues. Hip prostheses undergo various types of stress, i.e., fatigue stress, indicating its significance in manufacturing. Cold forging is a promising method to produce high-strength parts with high fatigue life. Titanium alloys are widely used in prostheses due to their corrosion resistance. This study investigates the feasibility of manufacturing hip prostheses via cold forging. To analyze the behavior of materials during the forging process, the FEM simulation by ABAQUS software is applied. The press force is a significant factor in achieving the final geometry in which raw material fills the forging die within one stroke. In addition, the strength of the die is noticeable during the forging process.