Predicting the Fatigue Life of a Ball Joint

The technical conditions and service life of steering elements of vehicles are an important factor directly affecting road safety. Therefore, high reliability of such kind’s components is required. In the paper, on the basis of the stand test, the fatigue durability of a ball joint of a steering tie rod is determined. It is elaborated together with a prediction for the further number of cycles, enabling to determine the technical state of the tested component containing its service life. The aim of the article is to select an appropriate mathematical model with respect to describing the relationship between the moment of force and the fatigue cycles performed for the ball joint of a steering rod of a vehicle with a GVW above 3.5 tonnes, and identifying the model’s parameters. As a result, the limit number of loading cycles after which the examined joint does not meet safety requirements is estimated.

Analysis of multiple failure behaviors of steering knuckle ball hinge of multi-axle heavy vehicle

The ball hinge is a key component of the vehicle chassis that connects the steering knuckle and the control arm. The study analyzed the multiple failure behaviors of the chassis ball hinge. Firstly, according to the macroscopic failure characteristics of the ball hinge, the fault tree analysis method was adopted to identify the possible cause of the failure. Then, the axial load and radial load on the ball joint were obtained by simulating the force of the vehicle under the typical extreme conditions. The stress distribution of the ball pin was obtained by finite element analysis of the ball joint. The calculation results are consistent with the fatigue crack position of the ball hinge. Finally, the macro morphology and microstructure of the ball joint seat, ball bowl, dust cover and other parts matched with the ball hinge were analyzed to further verify the failure mode of the ball hinge. The results showed that the dust cover of the ball hinge was firstly aged and cracked, and the external dust and particles enter into the friction contact area of the ball hinge, which caused the ball pin and ball bowl to be stuck. During the operating of the vehicle, the ball pin undergoes unidirectional bending fatigue fracture in the stress concentration area at the root of the conical surface.

Steerable Surgical Instrument for Conventional and Single-Site Minimally Invasive Surgery

Background. This article aims to present an innovative design of a steerable surgical instrument for conventional and single-site minimally invasive surgery (MIS), which improves the dexterity and maneuverability of the surgeon while offering a solution to the limitations of current tools. Methods. The steerable MIS instrument consists of a deflection structure with a curved sliding joints design that articulates the distal tip in two additional degrees of freedom (DoFs), relative to the instrument shaft, using transmission by cables. A passive ball-joint mechanism articulates the handle relative to the instrument shaft, improves wrist posture, and prevents collision of instrument handles during single-site MIS procedures. The two additional DoFs of the articulating tip are activated by a thumb-controlled device, using a joystick design mounted on the handle. This steerable MIS instrument was developed by additive manufacturing in a 3D printer using PLA polymer. Results. Prototype testing showed a maximum tip deflection of 60° in the left and right directions, with a total deflection of 120°. With the passive ball-joint fully offset, the steerable tip achieved a deflection of 90° for the right and 40° for the left direction, with a total deflection of 130°. Furthermore, the passive ball-joint mechanism in the handle obtained a maximum range of motion of 60°. Conclusions. This steerable MIS instrument concept offers an alternative to enhance the application fields of conventional and single-site MIS, increasing manual dexterity of the surgeon and the ability to reach narrow anatomies from other directions.

No more rattling: biomechanical evaluation of a hexapod ring fixator free of play

Hexapod-ring-fixators have a characteristic rattling sound during load changes due to play in the hexapod struts. This play is perceived as unpleasant by patients and can lead to frame instability. Using slotted-ball-instead of universal-joints for the ring-strut connection could potentially resolve this problem. The purpose of the study was to clarify if the use of slotted-ball-joints reduces play and also fracture gap movement. A hexapod-fixator with slotted-ball-joints and aluminum struts (Ball-Al) was compared to universal-joint-fixators with either aluminum (Uni Al) or steel struts (Uni Steel). Six fixator frames each were loaded in tension, compression, torsion, bending and shear and mechanical performance was analyzed in terms of movement, stiffness and play. The slotted-ball-joint fixator was the only system without measurable axial play (<0.01 mm) compared to Uni-Al (1.2 ± 0.1) mm and Uni-Steel (0.6 ± 0.2) mm (p≤0.001). In both shear directions the Uni-Al had the largest play (p≤0.014). The resulting axial fracture gap movements were similar for the two aluminum frames and up to 25% smaller for the steel frame, mainly due to the highest stiffness found for the Uni-Steel in all loading scenarios (p≤0.036). However, the Uni-Steel construct was also up to 29% (450 g) heavier and had fewer usable mounting holes. In conclusion, the slotted-ball-joints of the Ball-Al fixator reduced play and minimized shear movement in the fracture while maintaining low weight of the construct. The heavier and stiffer Uni-Steel fixator compensates for existing play with a higher overall stiffness.

A Study on Wear and Friction of Passenger Vehicles Control Arm Ball Joints

The following paper describes research on vehicle suspension elements: the ball joints. The worn surface roughness of selected ball pins and their bearings was compared in terms of vehicle mileage, utilization period, and car model. Ball pin roughness was measured using a scanning tunneling microscope (STM), whereas for the bearing surface, a profilometer was used. The aim of this study was to determine the resistive torque in an unloaded ball joint. Using the finite element method, models of the unloaded ball joint were analyzed in two scenarios: with and without interference between the worn ball and its bearing. Calculated values of resistive torques in the ball joint were compared, and recommendations were given relative to the mileage and the time after which it was necessary to perform verification or replacement of the ball joints.

Prosthetic foot design with biomimetic ankle mechanism

This thesis proposes a novel lower-limb prosthetic device. Current prosthetics either have overly simplistic designs with inaccurate biomechanics or use delicate microprocessors that are easily damaged in harsh environments. This thesis aims to address these concerns by creating a novel device that combines a pneumatic damping system with a ball joint, resulting in a robust design with improved biomechanics. This prosthetic offers an affordable alternative that can be completely rebuilt while providing added comfort through improved biomechanics. Overall, this thesis contributes to the literature by proposing and discussing an innovative design for an affordable, comfortable, biomechanically sound alternative for lower limb prostheses.

Tribological Properties of ZrO2 Coating on the Ball Joint of an Axial Piston Pump in High Water-Based Emulsion Medium

This paper studies the tribological properties of the ZrO2-coated spherical joint pair of the axial piston pump in a high water-based emulsion medium. Firstly, atmospheric plasma spraying was used to prepare the ZrO2 coating on the surface of the spherical joint pair. Secondly, the tribological characteristics of the steel-steel pair and ceramic-ceramic pair were analyzed by the friction and wear testing machine under the conditions of a high water-based emulsion concentration, load size, and load frequency. White light interference three-dimensional surface profiler and scanning electron microscope were used to analyze the original and worn surfaces of the samples, and then the friction and wear of the different material pairs were discussed. The results show that the friction reduction and wear resistance of the ceramic ball joint are superior to those of the steel ball joint. When the load is 100 N, the frequency is 1 Hz, and the emulsion concentration is 5%, and the friction coefficient and wear loss of the ceramic-ceramic ball joint pair are the lowest. The emulsion concentration and load have great influence on the friction coefficient and wear amount, while the frequency has little influence on them. With increasing concentration of the emulsion, the friction coefficient decreases and tends to be stable, but with increasing of load, the friction coefficient and wear increase. The friction coefficient and wear loss of the ceramic-ceramic ball joint in pure water are 0.25 times higher than those of the steel ball joint under the same working conditions. Therefore, when the concentration of the high water-based emulsion is 5%, 100 N load, 1 Hz frequency, the ceramic-ceramic ball joints display the best friction and wear resistance of the two. The research results provide a theoretical basis for the design, manufacture, and application of the ceramic coating hydraulic components in a high water-based emulsion medium.