The assembly of the fibula cutting guide with the metal insert design is used for bone cutting purposes where a surgeon inserts the cutting tool through the cut opening present in the outline for a metal insert. During the operation significant amount of forces is generated along the volume of the cutting guide body including at the point of contact between the bones and metal screw inserts that keep the bone in place. Such an amount of force generates stresses, which can be significant enough to break parts of the cutting guide body or the screws. The Finite element analysis of the whole assembly is crucial in understanding the distribution of these stress at different parts of the assembly which is then compared with the yield strength of the material used. The amount of stress generated at all times should be lesser than the yield strength of the material.

The cutting tool was tested under the 3 conditions:

• Apply a constant pressing force of 90N on the cutting tool to remove the material on the bone.

• Set the rotational velocity of the cutting guide to 2000 rad/s (=20,000 rpm).

• Set the general join to rotate around the x-axis for 6°.

The snap-fit was tested under another boundary setting:

• The contact between the 2 components was assigned as frictionless and frictional later.

• 100 N force was applied.

The simulation was done based on the scenario in which the first screw is drilling into the bone with the help of the cutting guide. Only the cutting guide pieces which connect directly with the screw are taken into consideration.

• Force F = 80 N pressing downward on the head of the screw.

• Moment M = 100 N*mm clockwise acting on the screw.