World Applied Sciences Journal 26 (3): 366-373, 2013 ISSN 1818-4952 © IDOSI Publications, 2013 DOI: 10.5829/idosi.wasj.2013.26.03.1517 Corresponding Author: Muhammad Abid, Faculty of Mechanical Engineering, Ghulam Ishaq Khan Institute of Engineering Sciences and Technology, Pakistan. 366 Implementation of Integrated Process Plan for an Artificial Hip Implant Muhammad Abid and M.W. Al-Grafi 1 2 Faculty of Mechanical Engineering, 1 Ghulam Ishaq Khan Institute of Engineering Sciences and Technology, Pakistan Department of Mechanical Engineering, 2 Taibah University, Al-Madina Al-Munawara, Saudi Arabia Submitted: Sep 6, 2013; Accepted: Nov 5, 2013; Published: Nov 15, 2013 Abstract: This paper is about the implementation of design process for an artificial human hip joint. It includes need analysis, material characterizations, stress analysis, die design and process plan development. Two implant samples manufactured locally and imported are used during this study. Material characterization is performed using Energy Dispersive X-ray Analysis, Optical Microscopy and Mechanical Testing. Using optical scanning electron microscopes, fractro-graphy is also performed for any defects in the implants such as fractures. In addition to the process plans suggested for the manufacturing of local and imported implants based on the information, an integrated process plan is also recommended. At the end, a die designed using Pro-Engineer software for the implant is also discussed. Key words: Artificial Hip Implant Design Process INTRODUCTION generally accepted as the common cause for infection and Prosthetics are artificial devices that are mounted to socket (ace tabular cup) and makes the motion possible the skeletal system of the human body to support or for a person. Femur Stem is the stem part of the implant to replace broken bones. Orthopedics is an $8.5 billion be inserted into the femur bone. For hip implant market that has been growing at an overall rate of 7% per replacement, total, partial (hemi-arthroplasty) and hybrid year. The total joint reconstruction (TJR), the largest implant replacement methodologies are adopted using market segment (41% of the total) is growing at 3-4%. cement less and cemented hip implants. Anatomy of the This market consists of knee implants (55%), hip implants implant is shown in Fig. 1b. (41%) and further extremities (4%), which include To achieve same functionality and performance of the shoulders, wrists and ankles. Only in America, there are original implant replaced with the artificial implant, with 3.6 million orthopedic surgeries in a single year. Due to complicated shapes, suitable interaction with body parts lack of necessary technical expertise and quality implants makes their study, analysis and fabrication complicated. being manufactured in a developing countries, result in Present study is performed for need analysis (customer unaffordable cost by the patients for imported implants. and industrial survey), material characterization, Over the past few years an increase in the simulation of manufacturing process plan and die design replacement of human joints due to their malfunctioning for artificial human hip joint implants. For this study, is increased avoiding the use of medication. Among all samples are arranged from hospitals made locally and the bone or body replacements that are done around the imported during surveys for need analysis. globe, the greatest frequency of replacement is highest in Orthopedic Implants and reasons showing need for their Need Assessment Using Industrial Surveys: Results of replacement is shown in Fig. 1a. An artificial human hip the industrial survey undertaken given in Table-1 show joint implant consists of Ace tabular Cup which is a very little number of locally manufactured implants; attached at the pelvis bone and socket of the hip joint. hence a high cost is paid to meet demand by importing It wears out with time and wear debris produced is implants. loosening of the implant. Femoral Head articulates in the