Designing Experimental Methods to Predict the Expansion Ratio of EVA Foam Material and Using Finite Element Simulation to Estimate the Shoe Expansion Shape

Jeng, Y.H.; Liu, De‐Shin; Yau, Hong-Tzong

doi:10.2320/matertrans.m2012178

Cited by 7 publications

(6 citation statements)

References 9 publications

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“…With the rapidly developing computer-aided design (CAD) technology, three-dimensional (3D) design of orthotic insoles can be made for various foot contours with optimal fit and minimum production cost and design time ( Ye et al., 2008 ). Additionally, reverse engineering and reverse innovative design (RID) allow the rapid production of insoles with highly accurate and precise size ( Dombroski et al., 2014 ; Jeng et al., 2012 ; Xia, 2014 ). Practically, the contour of foot abnormalities can be scanned by a 3D scanner providing accurate 3D data, which can subsequently be used in a subtractive manufacturing process of insoles (either adaptive manufacturing using a 3D printer or a CNC milling machine) ( Munro, 2005 ; Li et al., 2017 ).…”

Section: Introductionmentioning

confidence: 99%

Advanced design and manufacturing of custom orthotics insoles based on hybrid Taguchi-response surface method

Anggoro

Bawono

Jamari

et al. 2021

Heliyon

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Herein, a machining strategy to fabricate custom orthotic insoles with high surface finish and wide fit tolerance is presented. CNC milling was used to machine ethylene-vinyl acetate (EVA) foam for insoles with various surface hardness, and the Taguchi-response surface method (TM-RSM) was adopted to optimize the parameters of the CNC milling process (cutting speed, feed rate, tool path strategy, and step over). EVA foam with varying surface hardness and the tolerance of the wide fit insoles corresponding to the surface roughness were analyzed. Subsequently, a mathematical model was established to determine the optimal CNC milling parameters for a standard milling cutter under dry coolants. The results of the six parameters corresponding to the mean values of surface roughness were initially examined using the signal-to-noise ratio of the Taguchi method (TM). The surface roughness obtained with the TM-RSM was up to 4.13% higher than that obtained with the TM. The EVA foam insole with a surface hardness of 50–60 HRC and a wide fit tolerance of 0.75 mm provided the ideal level of comfort and support for patients with diabetes. The results of this study demonstrated that CNC milling provided a better surface finish of orthotic shoe insoles than other methods, which can serve as guidance in the development of machining strategies for insoles made from EVA foam.

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Section: Introductionmentioning

confidence: 99%

Advanced design and manufacturing of custom orthotics insoles based on hybrid Taguchi-response surface method

Anggoro

Bawono

Jamari

et al. 2021

Heliyon

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“…The aim of the present study was to determine how to lower the peak plantar heel pressure with different shoe parameter combinations based on a complete foot–shoe FE model developed through reverse engineering ( Jeng et al, 2012 ) and the Taguchi method. We hypothesized that all design parameters significantly affect the peak plantar pressure and that there exists an optimal combination to minimize it.…”

Section: Introductionmentioning

confidence: 99%

Design feature combinations effects of running shoe on plantar pressure during heel landing: A finite element analysis with Taguchi optimization approach

Yang

Cui²,

Wan³

et al. 2022

Front. Bioeng. Biotechnol.

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Large and repeated impacts on the heel during running are among the primary reasons behind runners’ injuries. Reducing plantar pressure can be conducive to reducing running injury and improving running performance and is primarily achieved by modifying the design parameters of running shoes. This study examines the effect of design parameters of running shoes (i.e., heel-cup, insole material, midsole material, and insole thickness) on landing peak plantar pressure and determines the combination of different parameters that optimize cushion effects by employing the Taguchi method. We developed the foot–shoe finite element (FE) model through reverse engineering. Model assembly with different design parameters was generated in accordance with the Taguchi method orthogonal table. The effectiveness of the model was verified using the static standing model in Ansys. The significance and contribution of different design parameters, and the optimal design to reduce plantar pressure during landing, were determined using the Taguchi method. In the descending order of percentage contribution was a conforming heel-cup (53.18%), insole material (25.89%), midsole material (7.81%), and insole thickness (2.69%). The more conforming heel-cup (p < 0.001) and softer insole (p = 0.001) reduced the heel pressure during landing impact. The optimal design of running shoe in this study was achieved with a latex insole, a 6 mm insole thickness, an Asker C-45 hardness midsole, and a 100% conforming heel-cup. The conforming heel-cup and the insole material significantly affected the peak plantar pressure during heel landing. The implementation of a custom conforming heel-cup is imperative for relieving high plantar pressure for long-distance heel-strike runners.

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“…[16] predicted the influence of parameters namely spindle speed, deep of cut, feedrate and diameter size of the tool on the roughness of the surface of the milling machine with experimental design. [17] used experimental design methods to predict the Expansion Ratio of EVA foam material and used Finite Element Simulation to estimate Shoe Expansion Shape. [18] examined the selection of optimal ordering parameters such as spindle speed, depth of cut (doc), and feedrate for advance workmanship in milling process in the calculation of surface roughness and maximizing material removal rate.…”

Section: Introductionmentioning

confidence: 99%

Advanced Manufacturing Process of Orthotic Shoe Insoles Using A New Material Based on the Taguchi Methodology

Anthony¹,

Anggoro²,

Jamari³

et al. 2021

Proceedings of the 2nd Borobudur International Symposium on Science and Technology (BIS-STE 2020)

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Some people who have foot deformities such as diabetes often experience pain and difficulty wearing shoes. The optimization of advanced manufacturing based on CAM -CNC with EVA rubber foam material has not been optimal. Two new materials are proposed in this paper for manufacturing optimization through the experimental stage. Some people who have foot deformities such as diabetes often experience pain and difficulty wearing shoes. The optimization of advanced manufacturing based on CAM -CNC with EVA rubber foam material has not been optimal. Two new materials are proposed in this paper for manufacturing optimization through the experimental stage. Some people who have foot deformities such as diabetes often experience pain and difficulty wearing shoes. The optimization of advanced manufacturing based on CAM -CNC with EVA rubber foam material has not been optimal. Two new materials are proposed in this paper for manufacturing optimization through the experimental stage. The two new materials proposed in this paper provide very significant results when compared with EVA rubber Foam. This new material can reduce the time needed to work on one pair of insoles to 6.0 hours / pair (75% faster) with an average surface smoothness of 7.54µm. The output of this research has significant implications for researchers and the manufacturing industry in the field of the shoe design; optimization of shoe manufacturing on CAM and CNC maching. This research also has implications for the use of modern computer-aided reverse engineering systems.

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Designing Experimental Methods to Predict the Expansion Ratio of EVA Foam Material and Using Finite Element Simulation to Estimate the Shoe Expansion Shape

Cited by 7 publications

References 9 publications

Advanced design and manufacturing of custom orthotics insoles based on hybrid Taguchi-response surface method

Advanced design and manufacturing of custom orthotics insoles based on hybrid Taguchi-response surface method

Design feature combinations effects of running shoe on plantar pressure during heel landing: A finite element analysis with Taguchi optimization approach

Advanced Manufacturing Process of Orthotic Shoe Insoles Using A New Material Based on the Taguchi Methodology

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