Recommendations for tool-handle material choice based on finite element analysis

Simulation of low-energy impacts on the human hand for prediction of peak reaction forces and bone fracture

Hands of workers in extractive and heavy-duty industries are susceptible to suffering injuries of varying severity. Improved safety procedures and new technologies for production and maintenance tasks have contributed to reducing the severity of injuries. However, manual tasks with high-risk factors can still lead to hand injuries. Hand bone fractures and dislocations can be caused by relatively small objects impacting a region of the hand at velocities in the range of 1.3 to 1.6 m per second. This impact can produce significant functional, physical, and psychological consequences in those affected and result in high costs derived from medical care. This study presents the results of a finite element simulation study conducted to reproduce impacts with energies in the range of 7 to 10 Joules of an object on the dorsal region of the hand. Simulation results are compared to previous experimental results obtained from controlled impact tests performed using cadaveric hand specimens. The vertical peak reaction force (PRF) as a function of the impact position was used as a primary outcome for comparisons. Simulation results for all impact positions were within the standard deviation measured experimentally, with differences in the PRF values in the range of -5.3% to 4.9%. Bone stress analyses at the position of impacts showed the locations where the maximum principal stress exceeded the bone strength, as well as the variability in the correspondence between the stress distribution predicted by the FE models and the fracture rate distribution observed experimentally.

Development, fabrication and mechanical characterisation of auxetic bicycle handlebar grip

The auxetic cellular structures are one of the most promising metamaterials for vibration damping and crash absorption applications. Therefore, their use in the bicycle handlebar grip was studied in this work. A preliminary computational design study was performed using various auxetic and non-auxetic geometries under four load cases, which can typically appear. The most representative geometries were then selected and fabricated using additive manufacturing. These geometries were then experimentally tested to validate the discrete and homogenised computational models. The homogenised computational model was then used to analyse the biomechanical behaviour of the handlebar grip. It was observed that handle grip made from auxetic cellular metamaterials reduce the high contact pressures, provide similar stability and hereby improve the handlebar ergonomics.

Evaluation of the bio-dynamic response of the hand-arm system and hand-tool designs - A brief review

Hand-operated tools transmit a high magnitude of vibration exposure to the hand-arm system that causes occupational diseases. The health effects caused in various countries for the past years due to usage of hand tools are necessary to identify the occupational disorders. Researchers have conducted various studies on biological effects, hand-transmitted vibration exposure and biodynamic responses throughout the years. This article goes over each of these studies in detail, as well as identifying areas where more research is needed. The majority of studies deal with the following topics: general guidelines for hand-transmitted vibrations; assessment techniques of vibration exposure; hand-tool evaluation methods; influence of hand-tool design to overcome the biomechanical effects; and finite element modelling for quantifying vibration exposure. In response to this, understanding the biodynamic behaviour of the hand-arm system is useful for better ergonomic intervention in hand tools to reduce fatigue and increase comfort.

Subject-Specific Finite Element Modelling of the Human Hand Complex: Muscle-Driven Simulations and Experimental Validation

This paper aims to develop and validate a subject-specific framework for modelling the human hand. This was achieved by combining medical image-based finite element modelling, individualized muscle force and kinematic measurements. Firstly, a subject-specific human hand finite element (FE) model was developed. The geometries of the phalanges, carpal bones, wrist bones, ligaments, tendons, subcutaneous tissue and skin were all included. The material properties were derived from in-vivo and in-vitro experiment results available in the literature. The boundary and loading conditions were defined based on the kinematic data and muscle forces of a specific subject captured from the in-vivo grasping tests. The predicted contact pressure and contact area were in good agreement with the in-vivo test results of the same subject, with the relative errors for the contact pressures all being below 20%. Finally, sensitivity analysis was performed to investigate the effects of important modelling parameters on the predictions. The results showed that contact pressure and area were sensitive to the material properties and muscle forces. This FE human hand model can be used to make a detailed and quantitative evaluation into biomechanical and neurophysiological aspects of human hand contact during daily perception and manipulation. The findings can be applied to the design of the bionic hands or neuro-prosthetics in the future.

Finite element analysis to assess the biomechanical behavior of a finger model gripping handles with different diameters

Study aim: Interactions between the fingers and a handle can be analyzed using a finite element finger model. Hence, the biomechanical response of a hybrid human finger model during contact with varying diameter cylindrical handles was investigated numerically in the present study using ABAQUS/CAE.

Materials and methods: The finite element index finger model consists of three segments: the proximal, middle, and distal phalanges. The finger model comprises skin, bone, subcutaneous tissue and nail. The skin and subcutaneous tissues were assumed to be non-linearly elastic and linearly visco-elastic. The FE model was applied to predict the contact interaction between the fingers and a handle with 10 N, 20 N, 40 N and 50 N grip forces for four different diameter handles (30 mm, 40 mm, 44mm and 50 mm). The model predictions projected the biomechanical response of the finger during the static gripping analysis with 200 incremental steps.

Results: The simulation results showed that the increase in contact area reduced the maximal compressive stress/strain and also the contact pressure on finger skin. It was hypothesized in this study that the diameter of the handle influences the stress/strain and contact pressure within the soft tissue during the contact interactions.

Conclusions: The present study may be useful to study the behavior of the finger model under the static gripping of hand-held power tools.

A novel anatomical woodworking chisel handle

A novel anatomically shaped ("anatomical") woodworking chisel handle was developed for wood scraping operation. 18 students participated in an evaluation study to compare the new handle against seven readymade handles of ¾-inch bench chisels in the context of a standard wood scraping task. A comfort questionnaire for hand tools (CQH) and a hand-based pain map were used for evaluating and comparing the handles. 'Functionality' and 'sweating' were found to be the most and least important comfort concerns, respectively. Maximum pain was reported at distal digit 1, and least pain at proximal digit 4. The anatomical handle was rated best for most of the comfort descriptors, least painful for most hand regions and took the least time for a standardized task.

SIMPLIFIED VERSUS REAL GEOMETRY FINGERTIP MODELS: A FINITE ELEMENT STUDY TO PREDICT FORCE–DISPLACEMENT RESPONSE UNDER FLAT CONTACT COMPRESSION

Finite element fingertip models are useful tools to assess product ergonomics. While “real geometry” approaches provide accurate results, developing models requires medical images. “Simpified geometry” approaches have to date not been tested to see whether they can provide equally accurate results in terms of mechanical response, i.e. force-displacement response and dimensions of fingertip contact area. Four fingertip models were built either from medical images (Visible Human project) or from simplified geometries. Simulations of fingertip flat contact compression at 20[Formula: see text] were performed. A 2nd order hyperelastic material property was used to effectively reproduce the mechanical behavior of the fingertip. Models based on simplified geometries such as conics proved as accurate as models reconstructed from medical images. However, accurate positioning of the bony phalanx is paramount if a biofidelic mechanical response is to be reproduced.

MRI-based experimentations of fingertip flat compression: Geometrical measurements and finite element inverse simulations to investigate material property parameters

Modeling human-object interactions is a necessary step in the ergonomic assessment of products. Fingertip finite element models can help investigating these interactions, if they are built based on realistic geometrical data and material properties. The aim of this study was to investigate the fingertip geometry and its mechanical response under compression, and to identify the parameters of a hyperelastic material property associated to the fingertip soft tissues. Fingertip compression tests in an MRI device were performed on 5 subjects at either 2 or 4 N and at 15° or 50°. The MRI images allowed to document both the internal and external fingertip dimensions and to build 5 subject-specific finite element models. Simulations reproducing the fingertip compression tests were run to obtain the material property parameters of the soft tissues. Results indicated that two ellipses in the sagittal and longitudinal plane could describe the external fingertip geometry. The internal geometries indicated an averaged maximal thickness of soft tissues of 6.4 ± 0.8 mm and a 4 ± 1 mm height for the phalanx bone. The averaged deflections under loading went from 1.8 ± 0.3 mm at 2 N, 50° to 3.1 ± 0.2 mm at 4 N, 15°. Finally, the following set of parameters for a second order hyperelastic law to model the fingertip soft tissues was proposed: C₀₁=0.59 ± 0.09 kPa and C₂₀ = 2.65 ± 0.88 kPa. These data should facilitate further efforts on fingertip finite element modeling.

An information model to support user-centered design of medical devices

The process of engineering design requires the product development team to balance the needs and limitations of many stakeholders, including those of the user, regulatory organizations, and the designing institution. This is particularly true in medical device design, where additional consideration must be given for a much more complex user-base that can only be accessed on a limited basis. Given this inherent challenge, few projects exist that consider design domain concepts, such as aspects of a detailed design, a detailed view of various stakeholders and their capabilities, along with the user-needs simultaneously. In this paper, we present a novel information model approach that combines a detailed model of design elements with a model of the design itself, customer requirements, and of the capabilities of the customer themselves. The information model is used to facilitate knowledge capture and automated reasoning across domains with a minimal set of rules by adopting a terminology that treats customer and design specific factors identically, thus enabling straightforward assessments. A uniqueness of this approach is that it systematically provides an integrated perspective on the key usability information that drive design decisions towards more universal or effective outcomes with the very design information impacted by the usability information. This can lead to cost-efficient optimal designs based on a direct inclusion of the needs of customers alongside those of business, marketing, and engineering requirements. Two case studies are presented to show the method's potential as a more effective knowledge management tool with built-in automated inferences that provide design insight, as well as its overall effectiveness as a platform to develop and execute medical device design from a holistic perspective.

Justification for a 2D versus 3D fingertip finite element model during static contact simulations

The biomechanical response of a human hand during contact with various products has not been investigated in details yet. It has been shown that excessive contact pressure on the soft tissue can result in discomfort, pain and also cumulative traumatic disorders. This manuscript explores the benefits and limitations of a simplified two-dimensional vs. an anatomically correct three-dimensional finite element model of a human fingertip. Most authors still use 2D FE fingertip models due to their simplicity and reduced computational costs. However we show that an anatomically correct 3D FE fingertip model can provide additional insight into the biomechanical behaviour. The use of 2D fingertip FE models is justified when observing peak contact pressure values as well as displacement during the contact for the given studied cross-section. On the other hand, an anatomically correct 3D FE fingertip model provides a contact pressure distribution, which reflects the fingertip's anatomy.

A better way of fitting clips? A comparative study with respect to physical workload

The clip fitting task is a frequently encountered assembly operation in the car industry. It can cause upper limb pain. During task laboratory simulations, upper limb muscular activity and external force were compared for 4 clip fitting methods: with the bare hand, with an unpowered tool commonly used at a company and with unpowered and powered prototype tools. None of the 4 fitting methods studied induced a lower overall workload than the other three. Muscle activity was lower at the dominant limb when using the unpowered tools and at the non-dominant limb with the bare hand or with the powered tool. Fitting clips with the bare hand required a higher external force than fitting with the three tools. Evaluation of physical workload was different depending on whether external force or muscle activity results were considered. Measuring external force only, as recommended in several standards, is insufficient for evaluating physical workload.

Numerical simulation of pressure therapy glove by using Finite Element Method

Pressure therapy garments apply pressure to suppress the growth and flatten hypertrophic scars caused by serious burns. The amount of pressure given by the pressure garments is critical to the treatment adherence and outcomes. In the present study, a biomechanical model for simulating the pressure magnitudes and distribution over hand dorsum given by a pressure glove was developed by using finite element method. In this model, the shape geometry of the hand, the mechanical properties of the glove and human body tissues were incorporated in the numerical stress analyses. The geometry of the hand was obtained by a 3D laser scanner. The material properties of two warp knitted fabrics were considered in the glove fabric model that developed from the glove production pattern with 10% size reduction in circumferential dimensions. The glove was regarded an isotropic elastic shell and the hand was assumed to be a homogeneous, isotropic and linearly elastic body. A glove wearing process was carried in the finite element analysis and the surface-to-surface contact pressure between hand and glove fabric was hence obtained. Through validation, the simulated contact pressure showed a good agreement with the experimental interface pressure measurement. The simulation model can be used to predict and visualise the pressure distribution exerted by a pressure therapy glove onto hand dorsum. It can provide information for optimising the material mechanical properties in pressure garment design and development, give a clue to understand the mechanisms of pressure action on hypertrophic scars and ultimately improve the medical functions of pressure garment.

Finite element evaluation of the effect of fingertip geometry on contact pressure during flat contact

Several studies investigated the mechanical loads developing in the hands during the use of various products in order to enhance user's performance, increase satisfaction and lower the risk of acute and cumulative trauma disorders. Values of pressure discomfort (PDT) and pressure-pain threshold (PPT) were, hence, provided. PDT and PPT may differ significantly for each subject and area of the hand because of psychological and physiological factors. A finite element study of the effect of fingertip anthropometry and anatomy geometry on mechanical loads developed during grasping is carried out in this research in order to assess physiological aspects behind variations of PDT and PPT existing between different subjects. It is found that the underlying anatomical structure and geometry (especially of the bone) significantly affect contact pressure distributions and pressure peak values. The largest difference in peak contact pressure between two different fingertips was in fact 27% for the same applied force. Furthermore, contact pressure distributions varied significantly between different subjects. The findings of this research provide novel insight into the phenomena of human grasping and the variation of contact pressure from subject to subject.

Comparison of subjective comfort ratings between anatomically shaped and cylindrical handles

Most authors have provided diameter recommendations for cylindrical handle design in order to increase performance, avoid discomfort, and reduce the risk of cumulative trauma disorders. None of the studies has investigated the importance of determining the correct handle shape on the subjective comfort ratings, which could further improve the handles' ergonomics. Therefore, new methods based on a virtual hand model in its optimal power grasp posture have been developed in order to obtain customised handles with best fits for targeted subjects. Cylindrical and anatomically shaped handles were evaluated covering ten subjects by means of an extensive subjective comfort questionnaire. The results suggest large impact of the handle shape on the perceived subjective comfort ratings. Anatomically shaped handles were rated as being considerably more comfortable than cylindrical handles for almost all the subjective comfort predictors. They showed that handle shapes based on optimal power grasp postures can improve subjective comfort ratings, thus maximising performance. Future research should consider real conditions, since the comfort ratings can vary based on the specific task and by the tool selected for the task.