The Coning Designs for the Micro Forming of a Surgical Slit Knife Using FE Simulations

Abstract

This paper deals with problems in the coining process for manufacturing surgical slit knife using two-dimensional (2D) and three-dimensional (3D) finite element (FE) simulations. The FE simulations are performed to investigate the material flow, and especially stress distribution on the coining dies. The main objective of this paper is to study the feasibility of a coining process for manufacturing a given geometry of surgical slit knife without forming defects and die failure. Very high stress distribution on the coining dies is found by 2D simulations of the coining process that exceeds the strength limit of the die material. The optimum preform and preforming die geometry are determined by FE simulations in order to reduce the die stress. 3D simulations of the preforming and coining processes are conducted with the optimal design to show that the geometry of the product can be achieved without defects by the coining process.