A comparative study of the static and dynamic behavior of a new type of tubular structure with drop-offs used in lower limb prostheses is presented in this paper. Composite structures that present mass reduction, low cost, and excellent performance are a great challenge for many researchers. In order to overcome these difficulties, numerical and experimental methods are performed, generating results regarding natural frequencies, damping loss factors, and maximum compression load for five different setups for tubes with drop-offs. For the manufacture of the structures, three types of fabrics are considered: carbon, glass, and a carbon/aramid hybrid fabric. Beyond the three types of tubes, two more setups are created considering hybridization, with the inner ply manufactured with glass fabric, the outer ply of the first setup manufactured with carbon fabric, and the outer ply of the second setup manufactured with carbon/aramid hybrid fabric. The structural hybridization and insertion of drop-offs provide a reduction in the cost of material. Firstly, an optimization strategy using the Lichtenberg algorithm is executed, aiming at the basic material properties in relation to elasticity modulus, strain modulus, Poisson ratio, and density. Then, it is possible to perform numerical modal analysis using the Finite Element Method in Ansys® software with the aim of obtaining the first natural frequencies for each setup. Modal experimental tests before and after failure obtained in the compression test are performed to measure the first natural frequency and damping loss factor for each setup, providing a comparison between the dynamic behavior of the undamaged and damaged structures, and, posteriorly, the numerical and experimental modal results before failure are compared. The compression test is performed to measure the maximum compression load supported by each structure. The results revealed that the hybrid structure with drop-offs is an appropriate option that offers the best cost-benefit for pylon tubes.
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