STATIC STRUCTURAL ANALYSIS OF AN ANKLE

FOOT ORTHOSIS MODEL FOR

REHABITALIZATION
A PROJECT REPORT
Submitted
In the partial fulfillment of the Requirements for the
Award of the Degree of
BACHELOR OF TECHNOLOGY (B. Tech)
In
MECHANICAL ENGINEERING
By

Menda Raju - 171FA08030

Tamma Kamal nadh - 171FA08049

Under the guidance of

Dr Gamini Suresh
Associate Professor

Department of Mechanical Engineering

2020-21
 CERTIFICATE

This is to certify that the project report entitled “Static Structural Analysis of
an Ankle Foot Orthosis Model for Rehabitalization” by M. Raju bearing the
Reg. No. 171FA08030 and T. Kamal Nadh bearing Reg. No. 171FA08049,
being submitted for the award of B. Tech Degree in Mechanical Engineering.
The work is carried out by them under the guidance and supervision of Dr
Gamini Suresh Associate Professor from Department of mechanical
Engineering VFSTR

Dr Gamini Suresh External Examiner Dr. L. S. Raju

Project Guide HOD, MECH
 ABSTRACT

Motion is one of the fundamental aspects of life, without motion there will be
no life and walking is the most basic form of human motion, but there are
millions of people in this world who are unable to walk properly due to gait
disabilities. Locomotion is the way in which humans move from one place to
another. It is crucial to avoid anti-social behavior and anxiety over the loss of
mobility. Patients with musculoskeletal or neuromuscular dysfunction such as
stroke, multiple sclerosis, cerebral palsy and such are unable to walk due to
unstable ankles, either from injury or muscular imbalance. Therefore,
locomotion is one of the primary tasks to be acquired by a post-stroke and other
such patients. Ancillary equipment, such as orthosis is used to assist the patient
to maintain balance and to perform walking by moving ankle.

There are many devices that can be used to assist people suffering from gait
disabilities and Ankle Foot Orthosis(AFO) is one of them. It is a brace that
supports the movement by hampering the ankle and foot. AFO’s are externally
applied and intended to control position and motion of the ankle, compensate
for the weakness, or correct deformities.

In this project we performed the static structural analysis and shape

optimization on a scanned model of a passive Ankle Foot Orthosis based on
different materials and at different loads and meshing conditions so as to
analyze the AFO as well as to determine the best suited material for developing
AFO based on the obtained results
 CONTENT

1. Introduction
1.1 Gait Cycle
1.2 Complications of Foot Drop
1.3 Causes of Foot Drop
1.4 Symptoms of Foot drop
1.5 Normal gait Vs Drop foot gait:
2. Ankle Foot Orthosis (AFO)
2.1 Active AFO
2.2 Passive AFO
2.3 Significant challenges in fabrication of AFO:
2.4 Fabrication process of ankle-foot orthosis (AFO)
3. Methodology
3.1 Model
3.2 Modified Model
3.3 Static Structural Analysis
3.4 Materials and it’s Properties used in the analysis
3.4 Solution
4. Results and Discussions
 1. INTRODUCTION

Motion is one of the primary characteristic of life but there are a lot of people in
this world who are unable to walk normally due to gait disabilities. Basically
gait disability is the disorder of the movement which includes imbalance,
shuffling, frequent falls or staggering.

Foot drop gait or steppage gait is a kind of gait in which dropping of the
forefoot happens due to the weakness of ankle and foot dorsiflexors. Foot drop
or steppage gait is also known as drop foot is an anatomical problem where
there is a weakness or paralysis at the anterior portion of the muscles of the
lower leg. But this problem that generally takes place in the foot drop may be
temporary or permanent based on the main cause of the foot drop and this kind
of gait movement.

1.1 GAIT CYCLE

In general, there are two phases in the gait cycle as shown in Fig.1 starting from
0% to 100% which completes one cycle of gait. The two phases are Stance
Phase which consists of 60% of the gait cycle and other one is Swing Phase
which consists the remaining 40% of the gait cycle. Based on the phases stance
and swing are further subdivided. Starting from 0% to 10% its weight
acceptance where the stabilization of the limb, absorption of shock and
preservation of the progression of the body takes place.
 Fig. 1.1 Phases in walking

This phase can be broken down further into initial contact and loading
response. Initial contact consists of the first 3% of the gait cycle. In typical
gait, the heel strikes the ground and initiates the rotation over the heel to foot
flat to preserve progression. This motion is the first rocker of the gait
cycle. Loading response goes from 3-10% of the gait cycle. In this portion, the
knee flexes slightly in order to absorb shock as the foot falls flat on the ground,
stabilizing in advance of single limb support. Then from 11% to 60% is single
leg support which involves progression of the body over the foot and weight-
bearing stability. The first sub-phase of single limb support is mid-stance,
which is seen during the 11-30% of the gait cycle. During mid-stance, the shank
rotates forward over the supporting foot, creating the second rocker motion of
the cycle. This maintains the forward progression of gait. The second stage of
single support is terminal stance which goes from 31-50% of the gait cycle.
During terminal stance, the center of mass advances out in front of the
supporting foot. The heel raises of the ground as you roll onto the ball of the
foot, creating the third rocker motion of the cycle, and from 51-60% it is pre-
swing phase which is the transition phase between stance and swing, in which
the foot is pushed and lifted off of the ground.

Finally, from 61-100% its swing phase whose objectives are foot clearance over
the ground, forward swing of the limb and preparation of limb for stance
The swing phase can be broken down into sub-phases. First one is Initial
swing goes from 61-75% of the gait cycle. During initial swing, the hip, knee,
and ankle are flexed to begin advancement of the limb forward and create
clearance of the foot over the ground. Then comes the Mid-swing which goes
from 75-87% of the gait cycle. During mid-swing, limb advancement continues
and the thigh reaches its peak advancement. Finally, Terminal swing comes
into picture which is the final phase of the gait cycle going from 87-100% of the
cycle. During terminal swing, the final advancement of the shank takes place
and the foot is positioned for initial foot contact to start the next gait cycle.

1.2 COMPLICATIONS OF FOOT DROP

There are mainly four common complications caused by drop foot as shown in
Fig. 2.

➢ First, the patient cannot control the falling of their foot after a heel strike.
As a result, the foot slaps the ground on every step.
➢ The second complication is the inability of the patients to clear their toe
during the swing phase. This causes the patients to drag their toe on the
ground throughout the swing phase.

Fig 1.2 Foot Drop Complications

➢ Similarly, Waddling gait happens because of weakness in your hip girdle

and upper thigh muscles. To make up for the weakness, you sway from
side and your hip drops with each step.

➢ When you walk, your gait is made up of two phases: swing and stance.
When one leg moves forward (swing), the other leg stays still and keeps
 you balanced (stance). The main symptom of Swing-out gait can be seen
when one leg swings forward and the hip drops down and moves
outward.

➢ Steppage gait is the inability to lift the foot while walking due to the
weakness of muscles that cause dorsiflexion of the ankle joint.

1.3 CAUSES OF FOOT DROP

In general, Foot drop happens in a person due to the following reasons as shown
in Fig. 3.

A. Multiple Sclerosis:

In this case, due to some damage suffered by myelin layer

surrounding the nerve, the message transmitted by the neurons get
slowed down when it enters the region of the damaged myelin
layer which results in the slowdown of the message transmission
and reception which leads to the foot drop.
Fig.3 shows an image of the difference between a nerve not
afflicted and afflicted by Multiple Sclerosis.

Fig. 1.3 Multiple Schelrosis

B. Pinched or damaged Peroneal nerve:

 Similar to the first case, due to the damage on the peroneal nerve,
the reception of the message sent from the brain gets delayed
leading to the slow reaction which results in foot drop.
Fig. 4 shows a diagram of common peroneal nerve near tibia and
fibula bone.

Fig. 1.4 Damaged Peroneal Nerve

C. Cerebral Palsy:

This is a disorder that is caused due to the damage of brain or

abnormal brain development before birth or early in life that affects
the person’s ability to move and maintain balance and posture.
Fig. 5 shows different types of common cerebral palsy.

Fig. 1.5 Cerebral Palsy Types

D. Brain Stroke:
 This is also one of the major cause of the foot drop. In this case due
to the dysfunction of the brain due to the causes shown in Fig. 6
transmission of the messages from the brain gets slowed down
which finally results in the slow reaction of the recepant.

Fig. 1.6 Reasons of Brain Stroke

1.4 Symptoms of Foot drop

– Difficult or unable to lift the foot

– Foot drags on the ground while walking
– Thigh is raising higher than normal to avoid dragging (high stepping gait)
– The foot gives out pain or feels numb when moving or lifting

1.5 Normal gait vs Drop foot gait:

In normal gait while starting a cycle the heel strikes the ground at first and then
the foot land on the ground flatly. Then that foot in on itself pushes off and
makes a clearance for the foot from the floor and then heel strike occours
concluding a complete cycle as shown in the Fig. 7 (A)
 Fig. 1.7 Difference b/w Normal and Foot Drop gait

But that is not the case in Drop foot gait, as heel strike doesn’t happen in this
cycle and foot directly lands flatly on the ground due to this there will be a
problem while inhibiting the push-off where results in low or no clearance while
moving forward so the person must hip-hike so as to prevent discomfort which
leads to another flat foot completing a cycle as shown in Fig. 7(B)

Hence, to alleviate the above mentioned problems it has become necessary to

fabricate a device that supports the gait. So many devices were developed and
Ankle Foot Orthosis is one of them. But before fabricating any model one has to
analyze it so as to prevent later complications. So forecasting is needed on the
device. So a model is developed and analyzed to predict the problem

2. ANKLE FOOT ARTHOSIS (AFO):

It is a mechanical device used in medical field to support and align the ankle
and foot, by assisting weak and paralyzed muscles of the ankle and foot, to
prevent deformities.

The purpose ankle foot orthosis is mainly designed to provide support and
 proper joint alignment of the foot and ankle, assistance in instance of muscle
weakness and helping protect the foot and leg. AFO’s are typically made of
plastic, carbon-fiber, or metals, with various levels of rigidity based on the
needs of the individual.

• It is a support intended to control the position and motion of the ankle,

compensate for weakness, or correct deformities. AFOs can be used to
support weak limbs, or to position a limb with contracted muscles into a
more normal position. AFO’s can be made out of wood, leather,
composites such as carbon composites, and plastics due to 3D printing.

Fig. 8 shows a basic Ankle Foot Orthosis model made of different materials
and their evolution starting from wood to carbon fiber composites.

Fig. 2.1 Materials used in AFO development

AFO is a specially designed supportive medical device which is intended to

i. control the motion of the ankle and sub-talar joints,

ii. compensate for muscle weakness and drop foot,
iii. correct deformities in the ankle and sub-talar joints due to injuries due to
stroke, cerebral palsy and others

They are of two types namely, Active AFO and Passive AFO as shown in below
Fig. 9
 Fig. 2.2 AFO Types

2.1 ACTIVE AFO:

Active AFO is the type of AFO which possess the ability to interact with the
walking environment and act accordingly. These types of AFOs are
comprised of electronic control system, actuator, power system, and stiffness
control unit and so on. Below shown Fig. 10 is a general Active AFO

Fig. 2.3 Active AFO

2.2 PASSIVE AFO:

A typical passive AFO is a device which provides constant torsional stiffness

that limits the motion of the ankle. It also braces the change in the stiffness of
the SMA(Shape Memory Alloy) wire is similar to the natural change in stiffness
of the ankle joint in normal gait. Fig. 11 shows a general Passive AFO.

Fig. 2.4 Passive AFO

2.3 Significant challenges in fabrication of AFO:

▪ Labour intensive and long fabrication time,

▪ Limited material selection,
▪ Limited design flexibility, and
▪ Dependence on the technician’s skill to achieve quality consistency

2.4 Fabrication process of ankle-foot orthosis (AFO):

Currently, AFOs can be made by using one of the methods stated below

▪ Thermoforming polymer sheets around a plaster cast impression

▪ Pre-preg carbon fiber sheet layup using plaster cast base as reference
surface.
▪ 3D printing or Additive manufacturing

2.5 Steps involved in fabrication of custom AFO:

▪ Measurement of the ankle and foot

 ▪ Creating a positive model based on negative plaster impression mold,
▪ Modifying the positive plaster model to match the anatomy of the patient
▪ Vacuum thermoforming of the AFO and fitting to the patient

3. Methodology

3.1 Model
Already fabricated Ankle Foot Orthosis (AFO) was held stationary and it was
scanned. The scan data of the AFO was then imported into MeshLab so that
voids could be filled and smoothing filter could be applied. The scan data was
then exported from MeshLab and imported into CREO Parametric CAD
software. Three key reference points along the sagittal plane were located and
used to define a central plane.The scan data was then oriented so that cross
sections could be taken following the legs curvature in that central plane. A
spline was fitted to each cross section to produce a mathematical model of the
legs surface. Finally AFO was designed as shown in Fig. 3.1 by intersecting the
leg surfaces with a second surface and defining the bounds of the AFO and
removing any overlapping material. The AFO surface can then be solidified to
the desired thickness based upon the strength and fit required.

Fig. 3.1

So we provided it with a thickness of 4mm by using pull option after selecting

the section that is to be extruded as shown in the Fig. 3.2.
 Fig. 3.2

3.2 Modified Model

In this case, we have modified our scanned AFO model in such a way that it
increases its capability.

The model is to split the AFO in three parts that is calf, connector and foot
respectively. But the main concern in this case is that the dual material
assignment is provided and the connector material is fixed that to be of CFRP
but that of calf and foot will be altering based on their material properties.

Fig. 3.3 shows Calf segment of the AFO model that is yet to be assembled
 Fig. 3.4 shows the connector segment of the AFO model which is yet to be
assembled

Fig. 3.5 shows the foot segment of the AFO model which is yet to be assembled

The calf, connector and foot segments are fragmented in SpaceCalim in the
geometry where these parts are also assembled which is shown in below Fig.
3.6
 Fig. 3.6 Assembled Model
3.3 Static Structural Analysis
The main objective of this project is the structural analysis of an AFO model.
The analysis has been performed in the ansys workbench 2021 R1 student
version.
In the workbench, from the toolbox, static structural analysis system was
dragged into the project schematic which is shown in the Fig. 3.7

Fig. 3.7 Workbench Project

Now, the we have already selected static structural analysis, we imported the
model into geometry by right-clicking import geometry
 Fig. 3.8

But the initial model that we currently posses is without any thickness, so we
again right-clicked on geometry and clicked on ‘Edit Geometry in SpaceClaim’
as shown in Fig. 3.8.

Model
Now that we provided the model with thickness, we have selected the edit
option by right clicking on model in the workbench and opened it. The
coordinate systems and the connections are left unaltered as shown in Fig. 3.9.

Fig. 3.9
Modified Model
We then selected the mesh, where we inserted the face sizing and refinement
after selected all the faces of our model. The sizing of the mesh is set at 15mm
respectively. Then we finally generated the mesh as shown in below Fig. 18.
Then this model that is assembled in the SpaceCalim is then edit in the model
which is shown in the below Fig. 3.10

Fig. 3.10

Meshing of Model

Fig. 3.11

Meshing of Modified Model

After right-clicking on the ‘Edit’ option in the model. We get into the
mechanical section of the workbench where the further steps could be preceded.
The materials is then assigned for the calf, connector and the foot as ABS,
CFRP and ABS respectively. But the connections and the coordinate systems
are left untouched.

In the mesh section, face sizing is provided with geometry for the face sections
with the element size as 15mm and then the mesh was generated as shown in
the below Fig. 3.12.

Fig. 3.12

Applying Supports and Loads for Model

After generating the mesh, we selected the static structural from the model tree
and inserted fixed support as shown in the figure below Fig. 3.13.
 Fig. 3.13

Then we inserted force in the similar manner as we did in case of fixed support
but in this case the force is 50N. The force applied is shown in Fig. 3.14.

Fig. 3.14

Applying Supports and Loads for Modified Model

Now that the mesh is generated, by right clicking on the static structural we
imported the fixed support and provided the reigon that we want to be fixed
applied which is provided in below figure Fig. 3.15
 Fig. 3.15
After provided the fixed support, we assign the forces by importing the forces
from the static structural and selecting the region to apply along with magnitude
which in this case is 50N and direction which is towards the calf. Below is an
image of forces applied in Fig. 3.16

Fig. 3.16

3.4 Materials and it’s Properties used in the analysis

1. ABS
 Fig. 3.17

2. CFRP

Fig. 3.18

3. Poly-Ethylene
 Fig. 3.19

4. Poly-Propylene

Fig. 3.20
 5. Poly-Lactic Acid

Fig. 3.21

3.5 Solution

For Model
Finally at the solution option under the model table we inserted total
deformation and equivalent stress and solved it by right clicking on it. But
before that we assigned the material in this case which is ABS.
The obtained results for deformation and equivalent stress are as shown in
below Fig. 3.22 and Fig. 3.23 respectively.
 Fig. 3.22

Fig. 3.23

Similarly, the Total Deformation and Equivalent Stress is obtained for 100N
and 150N respectively which is depicted below in Table 1 and Table 2.
 Table 1

Table 2

Now that we obtained the solution of analysis for the AFO assigned with ABS
(Acrylonitrile butadiene styrene) material. Now we are assigning the CFRP
material whose properties are depicted in Fig. 23.
Repeating the process previously mentioned total deformation and equivalent
stress of AFO material assigned with CFRP is analyzed at 50N, 100N and 150N
respectively whose values are tabulated in Table 3 and 4.

Table 3
 Table 4

Similar to the case of ABS and CFRP, we now assign AFO with Poly-Ethylene
material whose properties are tabulated in Fig. 24.
Based on the assigned properties, workbench produced the results of total
deformation and equivalent stress of the imported model whose values are
tabulated below in Table 5 and Table 6.

Table 5

Table 6

Now that we already analyzed materials such as ABS, CFRP and Poly-
Ethylene, now we assign Poly-Propylene as the new material whose properties
are tabulated in below Fig. 25.
Total deformation and equivalent stress of AFO material assigned with Poly-
Propylene is analyzed in similar manner at 50N, 100N and 150N respectively
whose values are tabulated in Table 7 and 8.

Table 7

Table 8
The final material that we are assigning for static structural analysis is Poly-
Lactic Acid, whose properties are depicted in the below Fig. 26.
Total deformation and equivalent stress of AFO material assigned with Poly-
Lactic Acid is analyzed at 50N, 100N and 150N respectively whose values are
tabulated in Table 9 and 10.

Table 9
 Table 10

For Modified Model

Finally after the load is applies on the AFO, we go to the solution and import
the total deformation and equivalent stress and solve it by clicking on it.
Below shows the Fig. 3.24 and Fig. 3.25 which is the solution of total
deformation and equivalent stress at 50N respectively.

Fig. 3.24
 Fig. 3.25

Similarly, the Total Deformation and Equivalent Stress obtained for 100N and
150N respectively which is depicted below in Table 11 in his case which is
ABS and CFRP whose properties are mentioned in Fig. 3.17and Fig. 3.18 and
as previously mentioned.

Table 11
Now, the properties of Poly-Ethylene and CRPF are used whose properties are
mentioned in Fig. 3.19 and Fig. 3.18 respectively. By using the previous
procedure we find the total deformation and equivalent stress as shown in below
Table 12.

Table 12

Now, the properties of Poly-Propylene and CRPF are used whose properties are
mentioned in Fig. 3.20 and Fig. 3.18 respectively. By using the previous
procedure we find the total deformation and equivalent stress as shown in below
Table 13.

Table 13
Now, the properties of Poly-Lactic Acid and CRPF are used whose properties
are mentioned in Fig. 3.21 and Fig. 3.17 respectively. By using the previous
procedure we find the total deformation and equivalent stress as shown in below
Table 14.

Table 14

4. RESULTS & DISCUSIONS

The analysis was done for articulated ankle-foot orthosis with different
materials which includes ABS, CFRP, Poly-ethylene, Poly-Propylene, Poly-
Lactic acid. Under different loading conditions, the deformations and equivalent
stresses can be noticed. Then the articulated model was modified, that is, the
design of the model was modified into split piece connected with a connector.
Below graphs show these two models compared with each other.
 Fig. 4.1

The above graph shows the comparison between the articulated and modified
AFO under same loading conditions. It can be seen from the above graph that
the deformations increased for Modified AFO when compared to Articulated
AFO about a range of 220-225 %. In the similar manner, below shows the graph
related to the equivalent stresses developed at 50 N forces.

Fig. 4.2
Similar to deformations, the equivalent stress is also increased in modified AFO
as compared to Articulated AFO about a range of 130-175 %.

Similar to the above case, when Articulated AFO and Modified AFO are
compared in case of deformation and equivalent stress as shown in Graph 3 and
Graph 4 when a load of 100N is applied, there is an increase of 219-222% and
139-233% respectively for deformation and Stresses respectively.

Fig. 4.3

Fig. 4.4
 Just like in the previous cases, deformation and equivalent stresses are
compared for articulated AFO and modified AFO when load applied is
modified to 150N and the comparisons are depicted in the below graphs 5 and 6
respectively. The increase in the deformations and stresses are in the range of
219-222 % and139-233 % respectively.

Fig. 4.5

Fig. 4.6

According to the graphs shown above, it is found that when the articulated
model was modified by splitting, the maximum deformation is increased in
modified model by 225%. Besides, the maximum stress was increased by 233%.
The maximum deformation of the conventional model with CFRP is the lowest
(0.13518 mm, 0.27037 mm and 0.40555 mm for 50N, 100N and 150N
respectively) among of all the materials selected at all loading conditions so it is
taken as connector in the case of modified model.

Similarly, Poly-Lactic Acid and ABS are found to be the best material for
fabricating the AFO due to their low deformations that is 2.7058 mm,
5.4116mm and 8.1174mm for Poly-Lactic Acid and 4.212 mm, 8.424 mm and
12.636 mm respectively for ABS, when the loads are 50N, 100N and 150N for
both the cases.

CONCLUSION

To summarize, articulated AFO model has been developed. The maximum

deformations and equivalent stresses are obtained from the results. The
modified AFO model was developed by optimizing the design and the obtained
results have been compared with the articulated model. The comparison showed
an increase in the deflection when compared to the articulated model due the
removal of material and presence of connector.

Due to the deflection, the modified model is more flexible when compared to
the articulated model which is stiff and the due to the design modification, it is
more comfortable and convenient when compared to the articulated model.

Among all the materials used in analysis, ABS and Poly-Lactic acid are the best
suited for the fabrication of AFO due to their low deformations and equivalent
stresses, printability, optimal cost and stiffness.
 References

1. Badescu M, Purcar C and Badescu D. Ankle foot orthoses with wire insertion. Appl
Mech Mater 2013; 371 : 554-558.

2. Chu T and Reddy NP. Stress distribution in the ankle foot orthosis used to correct
pathological gait. J Rehabil Res Dev 1995; 32(4): 349-360

3. Gomes G, Lourenco I, Oliveira J et al., structural reinforcements on AFO’s: A study

using computer aided design and finite element method. In: Proceedings of the 2-17
IEEE 5th Portuguese meeting on bioengineering, coimbra,16-18 February 2017,pp.1-
4.New York:IEEE.

4. Munguia, J., Dalgarno, K., 2013. “Ankle foot orthotics optimization by means of
composite reinforcement of free-form structures”. 24th International Solid Freeform
Fabrication Symposium - an Additive Manufacturing Conference, SFF 2013, pp. 766–
776.
5. Takhakh A, M., Abbas S, M., 2018. “Manufacturing and analysis of carbon fiber knee
ankle foot orthosis”. Int. J. Eng. Technol. 7: 2236

6. Berry, D.A., 1981. “Composite materials for orthotics and prosthetics”. Orthot.
Prosthet. 40:35–43

7. M. A. Marques, E. Mendes, N. V. Ramos, V. C. Pinto, and M. A. Vaz. 2010. “Finite-

element analysis of ankle-foot orthosis to predict fracture conditions during gait”.
Conference paper: Proc. 1st ICH Gaia-Porto, Portugal, 2010.