Squeaking ceramics bearing surfaces have been recently recognised as a problem in total hip arthroplasty. The position of the acetabular cup has been alluded to as a potential cause of the squeaking, along with particular combinations of primary stems and acetabular cups. This study has used the finite element method to investigate the propensity of a new large diameter preassembled ceramic acetabular cup to squeaking due to malpositioning. A verified three-dimensional FE model of a cadaveric human pelvis was developed which had been CT scanned, and the geometry reconstructed; this was to be used to determine the behaviour of large diameter acetabular cup system with a thin delta ceramic liner in the acetabulum. The model was generated using ABAQUS CAE pre-processing software. The bone model incorporated both the geometry and the materials properties of the bone throughout based on the CT scan. Finite element analysis and bone material assignment was performed using ABAQUS software and a FORTRAN user subroutine. The loading applied simulated edge loading for rising from a chair, heel-strike, toe off and stumbling. All results of the analysis were used to determine if the liner separated from the shell and if the liner was toggling out of the shell. The results were also examined to see if there was a propensity for the liner to demobilise and vibrate causing a squeaking sound under the prescribed loading regime. This study indicates that there is a reduction in contact area between the ceramic liner and titanium shell if a patient happens to trip or stumble. However, since the contact between the liner and the shell is not completely lost the propensity for it to squeak is highly unlikely

The number of knee replacement surgeries have increased rapidly over the past few years. However, these implants can have limited life due to the issue of wear. An accurate lubrication model is an important component in understanding and designing joints to deliver lower joint wear and the risks associated with such wear. One of the main challenges in tribological modelling of the knee implant is capturing the effects of the complex geometry on the joint performance. Most current models assume a single point of contact, with zero pressure and deformation assumed elsewhere. Unlike the hip implant, which can be described as a circular or elliptical contact, the knee implant involves a geometry that cannot be easily approximated into a regular shape. For this reason, the elastohydrodynamic lubrication equations become computationally expensive and challenging to solve. Finite element methods are required to capture the complex geometry and calculate deformations and how they vary spatially over the joint surface. Furthermore, the irregularity and asymmetry of the geometry provides no guarantee that well-defined contact points exist. A mixed lubrication model for a human knee implant is presented, incorporating the irregularity of the knee geometry. Tribological conditions in the mixed lubrication regime are calculated using a statistically representative description of surface roughness. This approach involves using the flow factors approach of Patir and Cheng (1978), and the Greenwood and Tripp (1970) approach for asperity contact. From this, the evolution of both the gross geometry and the change in surface roughness due to wear is determined

Introduction. Wear phenomenon of ultra-high molecular weight polyethylene (UHMWPE) in hip and knee prostheses is one of the major restriction factors on the longevity of these implants. In retrieved hip prostheses with screw holes in the metal acetabular cup for fixation to the pelvis, the generation of cold flow into the screw holes is frequently observed on the backside of the UHMWPE acetabular cup liner. In most retrieved cases, the protruded areas of cold flow on the backside were located on the reverse side of the severely worn and deformed surface of the polyethylene liner. It would appear that the cold flow into screw holes contributes to increase of wear and damages of the polyethylene liner in hip prosthesis. Methods. In a previous study (Cho et al., 2016), we pointed out the generation of cold flow into the screw holes on the backside of the retrieved UHMWPE acetabular cup liner as shown in Figure 1. The primary purpose of this study was to investigate the influence of the cold flow into the screw holes on the wear of the polyethylene liner in hip prosthesis. In this study, computer simulations of the generation of cold flow were performed using the finite element method (FEM) in order to propose the design criteria about the cold flow of the hip prosthesis for improving the wear resistance of the polyethylene liner. We especially focused on the influence of polyethylene thickness and contact surface conformity on the generation of cold flow into the screw hole. Results. An example of the results of a series of the FEM simulations performed in this study is shown in Figure 2. This figure shows the distributions of the contact stress in the polyethylene liners. The graphs shown in Figure 3 are the summary of results of a series of the FEM simulations performed in this study. The graph in Figure 3(a) shows the changes in the maximum contact stress in the polyethylene liner with the thickness of polyethylene liner. The graph in Figure 3(b) shows the changes in the maximum contact stress in the polyethylene liner with the radial clearance between the femoral head and the polyethylene liner. Discussion and Conclusions. It was found that the magnitudes of cold flow and maximum contact stress in the polyethylene liner had a tendency to increase with decreasing the thickness of polyethylene liner. It was also found that the magnitude of cold flow and maximum contact stress in the polyethylene liner had a tendency to increase with increasing the radial clearance between the femoral head and the polyethylene liner. The results of this study suggest that polyethylene thickness and contact surface conformity have a significant influence on the generation of cold flow into the screw holes and wear of the polyethylene liner. For any figures or tables, please contact authors directly

Introduction. Ultra-high molecular weight polyethylene (UHMWPE) is the sole polymeric material currently used for weight- bearing surfaces in total joint replacement. However, the wear of UHMWPE in knee and hip prostheses after total joint replacement is one of the major restriction factors on the longevity of these implants. In order to minimize the wear of UHMWPE and to improve the longevity of artificial joints, it is necessary to clarify the factors influencing the wear of UHMWPE. A number of studies have investigated the factors influencing the wear of UHMWPE acetabular cup liner in hip prosthesis. Most of these studies, however, have focused on the main articulating surfaces between the femoral head and the polyethylene liner. Materials and Methods. In a previous study (Cho et al., 2016), the generations of cold flow into the screw holes in the metal acetabular cup were observed on the backside of the retrieved UHMWPE acetabular cup liners as shown in Figure 1. We focused on the screw holes in the metal acetabular cup (Figure 2) as a factor influencing the wear behavior of polyethylene liner in hip prosthesis. In this study, computer simulations of the generation of cold flow into the screw holes were performed using the finite element method (FEM) in order to investigate the influence of the screw holes in the metal acetabular cup on the mechanical state and wear behavior of polyethylene liner in hip prosthesis. Results. An example of the results of the FEM simulations performed in this study is shown in Figure 3. In the region which the cold flow into the screw holes occurred, it was found that locally high contact stresses which exceed the yield stress of UHMWPE and considerable plastic strains were generated throughout the overall thickness between the backside and top surface of the polyethylene liners. On the contrary, in the case of the polyethylene liner combined with the metal acetabular cup without screw hole, although the regions of high contact stress and high plastic strain had a tendency to be limited around contact surface compared with those of the combination with screw holes, the values of contact stress and plastic strain were lower than the combination with screw holes. Discussion and Conclusions. The results of this study suggest that the cold flow generated by the existence of the screw holes in the metal acetabular cup of hip prosthesis reduces the wear resistance of the UHMWPE acetabular cup liner. It would appear that the cold flow into the screw holes contributes to structural weakening of the UHMWPE and reduction of the polyethylene thickness, thus increase of internal stresses and plastic strains in and around the regions of cold flow. Therefore, it is required that improvement of the screw holes in the metal acetabular cup and/or improvement of fixation method of the metal acetabular cup to a pelvis in order to enhance the wear resistance of the polyethylene liner. For any figures or tables, please contact authors directly

Introduction. Ultra-high molecular weight polyethylene (UHMWPE) is the sole polymeric material currently used for weight- bearing surfaces in total joint replacement. However, the wear of UHMWPE in the human body after total joint replacement causes serious clinical and biomechanical reactions. Therefore, the wear phenomenon of UHMWPE is now recognized as one of the major factors restricting the longevity of artificial joints. In order to minimize the wear of UHMWPE and to improve the longevity of artificial joints, it is necessary to clarify the factors influencing the wear mechanism of UHMWPE. Materials and Methods. In a previous study (Cho et al., 2016), it was found that roundness (out-of-roundness) of the retrieved UHMWPE acetabular cup liner [Figure 1(a)] had a tendency to increase with increasing roundness of the retrieved metal femoral head [Figure 1(b)]. It appears that roundness of the femoral head contributes to increase of wear of the polyethylene liners. We focused on the roundness of femoral head as a factor influencing the wear of polyethylene liner in hip prosthesis. In this study, further roundness measurements for 5 retrieved metal femoral heads were performed by using a coordinate measuring machine. The elasto-plastic contact analyses between femoral head and polyethylene liner using the finite element method (FEM) were also performed in order to investigate the influence of femoral head roundness on the mechanical state and wear of polyethylene liner in hip prosthesis. Results. The range of roundness of the 5 retrieved metal femoral heads measured in this study was 14.50∼44.70 µm. Two examples of the results of FEM contact analyses are shown in Figure 2. Figure 2(a) is the results of the repeated contact analysis between femoral head and polyethylene liner under constant axial loading of 1000 N. Figure 2(b) is the results of the repeated contact analysis between femoral head and polyethylene liner under hip joint loading during normal gait. These figures show the distribution of the contact stress (von Mises equivalent stress) in the polyethylene liner. The graph in Figure 3 shows the changes in the maximum contact stress in the polyethylene liner with the flexion/extension angle of femoral head. Discussion and Conclusions. As the results of a series of the FEM contact analyses, it was found that repeated high contact stresses which exceed the yield stress of UHMWPE caused by roundness of the metal femoral head occurred in the polyethylene liner as shown in Figures 2 and 3. It was also found that the magnitude and amplitude of the repeated contact stresses had a tendency to increase with increasing roundness of the femoral head and axial loading applied to the femoral head. The results of this analytical study suggest that the roundness (out-of- roundness) of the femoral head is associated with accelerating and/or increasing wear of the UHMWPE acetabular cup liner in a hip prosthesis after total hip replacement. For any figures or tables, please contact authors directly

Introduction. Ultra-high molecular weight polyethylene (UHMWPE) is the sole polymeric material currently used for weight- bearing surfaces in total joint replacement. However, the wear of UHMWPE and the polyethylene wear debris generated in the human body after total joint replacement cause serious clinical and biomechanical reactions. Therefore, the wear phenomenon of UHMWPE in total joint replacement is now recognized as one of the major factors restricting the longevity of these implants. In order to minimize the wear of UHMWPE and to improve the longevity of artificial joints, it is necessary to clarify the factors influencing the wear mechanism of UHMWPE. Materials and Methods. The wear and/or failure characteristics of 33 retrieved UHMWPE acetabular cup liners of hip prostheses were examined in this study. The retrieved liners had an average in vivo duration of 193.8 months (75 to 290 months). Several examples of the retrieved liners are shown in Figure 1. The elasto-plastic contact analyses between metal femoral neck and polyethylene liner and between metal femoral head and polyethylene liner using the finite element method (FEM) were also performed in order to investigate the factors influencing the wear and/or failure mechanism of the polyethylene liner in hip prosthesis. Results. In the examination of the retrieved polyethylene liners, the generation of component impingement was observed in 24 cases of the 33 retrieved liners (72.7%) as shown in Figures 1(a) and (b). In addition, the generation of cold flow into the screw holes in the metal acetabular cup was observed in 27 cases of the 33 retrieved liners (81.8%) as shown in Figures 1(c) and (d). Several examples of the results of the FEM contact analyses are shown in Figure 2. In the simulation of the component impingement, it was found that high contact stresses which exceed the yield stress of UHMWPE and considerable plastic strains occurred in the rim of the polyethylene liner as shown in Figures 2(a) and (b). In the simulation of the cold flow, it was found that the stress concentration near the edge of screw hole has significant influence on the states of contact stresses and plastic strains in the surface and undersurface (backside) of the polyethylene liner as shown in Figures 2(c) and (d). Discussion and Conclusions. In this study, we focused on the impingement between the metal femoral neck and the polyethylene liner and the cold flow into the screw holes on the backside of the polyethylene liner as the factors influencing the wear and/or failure of the UHMWPE acetabular cup liner in hip prosthesis. The results of these retrieval and analytical studies confirmed that the component impingement and the cold flow into the screw holes contribute to increase of wear and/or failure of the polyethylene liner. Therefore, it is necessary to improve resistance to the component impingement and the cold flow in order to decrease the wear and/or failure of the UHMWPE acetabular cup liner and to increase the longevity of hip prosthesis. For any figures or tables, please contact authors directly

For the management of displaced patellar fractures, surgical fixation using cannulated screws along with anterior tension band wiring is getting popular. Clinical and biomechanical studies have reported that using cannulated screws and a wire instead of the modified tension band with Kirschner wires improves the stability of fractured patellae. However, the biomechanical effect of screw proximity on the fixed construction remains unclear. The aim of this study was to evaluate the mechanical behaviors of the fractured patella fixed with two cannulated screws and tension band at different depths of the patella using finite element method. A patella model with simple transverse fracture [AO 34-C1] was developed; the surgical fixation consisted of two 4.0-mm parallel partial-threaded cannulated screws with a figure-of-eight anterior tension band wiring using a 1.25-mm stainless steel cable. Two different locations, including the screws 5-mm and 10-mm away from the leading edge of the patella, were used. A tension force of 850 N was applied on the patellar apexes at two loading angles (45° and 0° [parallel] to the long axis) to simulate different loading conditions while knee ambulation. The proximal side (base) of the patella was fixed, and the inferior articular surface was defined as a compression-only support in ANSYS to simulate the support from distal femur condyles. Compression-only support enables the articular surfaces of the present patella to only bear compression and no tension forces. Under different loading conditions, the fixed fractured patella yielded higher stability during 0° loading of tension force than during 45° loading. When the screws were parallel placed at the depth of 5 mm away from the patellar surface, the deformation of patellar fragment and maximum gap opening at the fracture site were smaller than those obtained by screws placed at the depth of 10 mm away from the patellar surface. Compared to the superficial screw placement, the deeper placement (10 mm) increased the maximum gap opening at the fracture site by 1.56 times under 45° loading, and 1.58 times under 0° loading. The load on the tension band wire of the 10-mm screw placement was 3.12 times (from 230 to 717 N) higher than that of the 5-mm placement. Under the wire, the contact pressure on the patellar surface was higher with the 10-mm screw placement than the 5-mm screw placement. The peak bone contact pressures with the 10-mm placement were 7.7 times (99.5 to 764 MPa) higher. This is the first numerical study to examine the biomechanical effects of different screw locations on the fixation of a fractured patella using screws and tension band. Based on a higher stability and lower cable tension obtained by the superficial screws placement, the authors recommended the superficial screw placement (5 mm below the leading edge of the patella) rather than the deep screws while fixing the transverse patellar fracture with cannulated screws and cable

Bone remodeling effects is a significant issue in predicting long term stability of hip arthroplasty. It has been frequently observed around the femoral components especially with the implantation of prosthesis stem. Presence of the stiffer materials into the femur has altering the stress distribution and induces changes in the architecture of the bone. Phenomenon of bone resorption and bone thickening are the common reaction in total hip arthroplasty (THA) which leading to stem loosening and instability. The objectives of this study are (i) to develop inhomogeneous model of lower limbs with hip osteoarthritis and THA and (ii) to predict the bone resorption behavior of lower limbs for both cases. Biomechanical evaluations of lower limbs are established using the finite element method in predicting bone remodeling process. Lower limbs CT-based data of 79 years old female with hip osteoarthritis (OA) are used in constructing three dimensional inhomogenous models. The FE model of lower limbs was consisted of sacrum, left and right ilium and both femur shaft. Bond between cartilage, acetabulum and femoral head, sacrum and ilium were assumed to be rigidly connected. The inhomogeneous material properties of the bone are determined from the Hounsfield unit of the CT image using commercial biomedical software. A load case of 60kg body weight was considered and fixed at the distal cut of femoral shaft. For THA lower limbs model, the left femur which suffering for hip OA was cut off and implanted with prosthesis stem. THA implant is designed to be Titanium alloy and Alumina for stem and femoral ball, respectively. Distribution of young modulus of cross-sectional inhomogeneous model is presented in Fig. 2 while model of THA lower limbs also shown in Fig. 2. Higher values of young modulus at the outer part indicate hard or cortical bone. Prediction of bone resorption is discussed with the respect of bone mineral density (BMD). Changes in BMD at initial age to 5 years projection were simulated for hip OA and THA lower limbs models. The results show different pattern of stress distribution and bone mineral density between hip OA lower limbs and THA lower limbs. Stress is defined to be dominant at prosthesis stem while femur experienced less stress and leading to bone resorption. Projection for 5 years follow up shows that the density around the greater tronchanter appears to decrease significantly

Purpose. Medial tibial condylar fractures (MTCFs) are rare but a serious complication after unicompartmental knee arthroplasty (UKA). The reasons for MTCFs was thought to be associated with the surgical procedures that are the halls for the guide pins, extended cut of the posterior tibial cortex, an incorrect positioning of the tibial keel groove, and an excessive force application when placing the tibial component. However, the relationship between MTCFs and the alignment of the tibial component has not been proven. The purpose of the study was to investigate the effect of the tibial component alignment to the MTCFs using the finite element method (FEM). Materials and Methods. We used three-dimensional (3D) image model of the tibia (Sawbones: Washington, US) on the FEM analysis software (ANSYS Design Space ver. 12, Tokyo, Japan). We measured the bone stresses in the 3D image model of the tibia at the site of the medial metaphyseal cortex and the anterior/posterior cortex. The tibial component was placed 0°, 3°varus, 3°valgus, 6°varus, and 6° valgus relative to the tibial anatomical axis in the coronal plane (Figure 1). In sagittal plane, tibial component was positioned 7° posterior inclination relative to the tibial anatomical axis. And, making an additional vertical groove at the posterior cortex by the extended sagittal saw cut of 2° and 10° posterior inclination, the impact of posterior cortical bone stress was evaluated (Figure 2). A load of 900 N was applied to the center of the tibial component parallel to the tibial axis, the maximum bone stress was subsequently calculated. Furthermore, to evaluate the stress distribution, we calculated the bone mass of the 3D bone model below the tibia component under the various alignment of the tibial component (Figure 3). Results. The bone stress at the medial metaphyseal cortex and the anterior cortex did not change depending on the alignment of the tibial component (Figure 4). When the tibial component was placed varus, the bone stress at the posteiror cortex decreased. By contrast, the valgus position of the tibial component increased the bone stress. An extended sagittal saw cut increased the bone stress depending on the depth of the groove. The bone mass of the tibia below the tibial component decreased as positioning the tibial component valgus. Conclusions. Surgeons should be aware of the potential pitfalls of valgus alignemnt of the tibial component and an extended sagittal saw cut, because this can lead to increased risk of the MTCFs

The Birmingham Hip Mid Head Resection (BMHR) was designed to accommodate patients with lower quality bone in the proximal half of the femoral head. It is a relatively new conservative hip implant with promising early results. Finite element modelling may provide an insight into mid-term results. A cadaveric femur was CT scanned and 3D geometry of the intact femur constructed. The correctly sized BMHR implants (with and without visual stop) were positioned and these verified by a surgeon; hence constructing the post-operative models. Walking loads were applied and contact surfaces defined. Stress analyses were performed using the finite element method and contact examined. Also, a strain-adaptive bone remodelling analysis was run using 45% gait hip loading data. Virtual DEXA images were computed and were analysed in seven regions of the bone surrounding the implants. The BMHR was found to be mechanically stable with all surfaces indicating micromotion less than the critical 150 microns. Stress distribution was similar to the intact femur, with the exception of the head-neck region where some stress/strain shielding occurs. This is mirrored in the bone remodelling results, which show some bone resorption in this region. The visual stop, which is designed to ensure that the stem is not overdriven during implantation, did not affect the stress/strain results; only on a very local scale. There is minimal data available in the literature regarding conservative hip implants and no data regarding the BMHR. This study is the first to look at the mechanical response of the bone to this implant

Cannulated screw is commonly used in the fixation of proximal femoral neck fractures. In the literature, several configurations had been proposed for best mechanical support with clinical experiences or biomechanical tests. Although screws in triangle configuration contribute certain fixation stability, but sometimes the surgeons made their own choices have to conduct another fixation pattern for some factors such as fracture type, economic issues, and so on. Therefore the aim of this study is to analyze the mechanical responses of a fractured femur fixed with screws in different configurations, screw materials and screw diameters with finite element method, trying to find the most stable construct. A solid femur model was built from the CT images of a standard saw bone. Three fracture types of the femoral neck were created according to Pauwel's classification (30?, 50?, 70?) by CAD software. The models of implanted screws were built according to a commercial cannulated screw (Stryker Osteosynthesis, Schoenkirchen/Kiel, Germany) with diameter 6.5mm and 4.5mm by CAD software, too. Three fixation configurations were analyzed in this study, including triangle with superior single screw with titanium diameter 6.5mm, triangle with inferior single screw with diameter 6.5mm and diamond with four stainless screw diameter 4.5mm (fig.1). Totally there were nine models constructed in this study, and all of them were then imported into ANSYS WORKBENCH v14 (Swanson Analysis, Houston, PA, USA) to mesh and further analysis. 700N vertical downward force was applied on the femur head and the distal end of femur shaft was totally fixed. The triangle fixation with superior single screw resulted in a best stability, but the fracture fixed with screws in a diamond configuration has least fracture gap. The difference of the maximum displacement of the femur head with Pauwel's classification 70?between triangle fixation with superior single screw and diamond configuration is only 0.03mm (1.72–1.69 mm). In most unstable femoral neck fracture [Pauwel's classification 70], the maximum gap distance is 0.59mm under the diamond configuration, while it is 0.63mm as the fracture fixed with a triangle configuration. Therefore, this study suggests that four 4.5mm stainless screws in a diamond configuration is an alternative for proximal femur fracture once 6.5mm titanium screws are not available

Introduction. Total hip replacement is an established surgical procedure done to alleviate hip pain due to joint diseases. However, this procedure is avoided in yonger patients with higher functional demands due to the potential for early failure. An ideal prosthesis will have have a high endurance against impact loading, with minimal micromotion at the bone cement interface, and a reduced risk of fatigue failure, with a favourable stress distribution pattern in the femur. We study the effect of varying the material properties and design element in a standard cemented total hip using Finite Element Analysis. Methods. A patient-specific 3D model of femur will be constructed from CT scan data, while a Summit® Cemented Hip System (DePuy Orthopedic) will be used to as a control for comparative evaluation. We vary the material stiffness of different parts of the prosthesis(see Fig.1) to formulate a design concept for a new total hip prosthesis design; and use Finite Element Method to predict the micromotion of the hip prosthesis at the bone cement interface, as well as the stress distribution in the the femur. Result. Validation of computational protocol was being done by comparing the principal maximum strain of the femoral cortex along the diaphysis, and the amount of deflection, with published literature, similarly, contact modelling validation was also done. Model 1–4 induced lower peak Von Mises stress in the cement, which takes a much lower value than any of the cement mechanical limits postulated. Therefore, the risk of cement failure is greatly reduced in Model 1–4. However, the effect of varying stiffness in different regions is not significant in terms of load transmission to the cement. Micromotion at the bone-cement interface was studied via two approaches: Peak micromotion at the bone cement interface; and the micromotion data at 12 Regions of Interest (ROI)s. Both results showed that model 2 and 3 are capable of reducing micromotion at bone-cement interface, in comparison with the Summit® Cemented Hip System. By comparing the Von Mises Stress distribution in the proximal femur; model 1 is found to result in a significantly reduced stress shielding effect, while model 2–4 are also favourable in comparison to the standard Summit® prosthesis in terms of stress distribution in the femur. Figure 2 shows the effects of the performance of model 1–4, presented as percentage difference from the Summit® prosthesis. Model 1 is unfavourable, despite its favourable stress distribution, because its peak and overall micromotion at the bone-cement interface is greatly increased. Conclusion. Model 2 and 3 have favourable design elements. They both have reduced micromotion at the bone-cement interface; and a favourable stress distribution in the femur. Further refining and testing of model 2 and 3 should done, as these models may provide information which may be useful in improving the performance of the current range of total hip replacement prostheses

Introduction. Fretting corrosion at the taper interface has been implicated as a possible cause of implant failure. Using in-vitro testing, fretting wear observed at tapers of retrieved implants may be reproduced (Marriott, EORS-2014). In order to reduce time and cost associated with experimental testing, a validated finite element method (FE) can be employed to study the mechanics at the taper. In this study we compared experimental and representative FE simulations of an accelerated fretting test set-up. Comparison was made by between the FE wear score and volumetric material loss from the testing. Methods. Experimental test set-up: An accelerated wear test was developed that consistently reproduced fretting wear features observed in retrievals. Biomet stems with smooth 4° Type-1 tapers were combined with Ti6Al4V Magnum +9 mm adaptors using a 2 or 15 kN assembly force. The head was replaced with a custom head fixture to increase the offset and apply a torque at the taper interface. The stems were potted according to ISO 7206-6:2013. The set-up was submerged in a test medium containing PBS and 90gl-1 NaCl. The solution was pH adjusted to 3 using HCl and maintained at 37°C throughout the tests. For each assembly case, n=3 tests were cyclically loaded between 0.4–4 kN for 10 Million cycles. Volumetric wear measurements were performed using a Talyrond-365 roundness measurement machine. The FE model was created to replicate the experimental set up. Geometries and experimental material data were obtained from the manufacturer (Biomet). The same assembly forces of 2 and 15 kN were applied, and the same head fixture was used for similar offset and loading conditions. The 4 kN load was applied at the same angles in accordance with ISO 7206-6:2013. Micromotions and contact pressures were calculated, and based on these a wear score was determined by summation over all contact points. Results. The FE wear score showed a significant drop after an assembly force of 15 kN has been applied. The micromotion scores were similar, and the contact pressure was higher due to the larger assembly force. The volumetric wear measurements did not show a significant difference between the two assembly cases due to the large variation in measured values. A downward trend can be observed when applying higher assembly forces, similar to the trend seen at the FE wear score (figure 1, table1). Discussion. This study shows a correlation between experimental and FE simulation, however highlights the difficulty in validating a FE model with complex in-vitro experiments. Due to the nature of experimental testing, it is impossible to remove all sources of error associated with the set-up. The use of a single static load and the absence of fluids and corrosion processes means that the full mechanics of the wear process could not be fully replicated. Despite these deficiencies the general trends and wear patterns observed in the experimental setup were reproduced. Further studies will focus on including the interplay between the aforementioned properties, to provide a better simulation of the fretting processes occurring at the taper junction

Polymer foams have been extensively used in the testing and development of orthopaedic devices and computational models. Often these foams are used in preference to cadaver and animal models due to being relatively inexpensive and their consistent material properties. Successful validation of such models requires accurate material/mechanical data. The assumed range of compressive moduli, provided in the sawbones technical sheet, is 16 MPa to 1.15 GPa depending on the density of foam. In this investigation, we apply two non-contact measurement techniques (digital volume correlation (DVC) and optical surface extensometry/point-tracking) to assess the validity of these reported values. It is thought that such non-contact methods remove mechanical extensometer errors (slippage, misalignment) and are less sensitive to test-machine end-artifacts (friction, non-uniform loading, platen flexibility). This is because measurement is taken directly from the sample, and hence material property assessment should be more accurate. Use of DVC is advantageous as full field strain measurement is possible, however test time and cost is significantly higher than extensometry. Hence, the study also sought to assess the viability of optical extensometry for characterising porous materials. Testing was conducted on five 20 mm cubic samples of 0.32g/cc (20 pcf) solid rigid polyurethane foam (SAWBONESTM). The strain behaviour was characterised by incremental loading via an in situ loading rig. Loading was performed in 0.1 mm increments for 8 load steps with scans between loading steps. Full field strain measurement was performed on one sample by micro focus tomography (muvis centre, Southampton) and subsequent DVC (DaVis, Lavision). Average strains in each direction were then calculated to enable modulus and Poisson's ratio calculation. These results were subsequently corroborated by use of optical point-tracking (MatchID). To account for heterogeneities, axial strain measurements were averaged from six points on the front and rear surfaces (fig.2). In each test compressive displacement was applied to 900N (∼2MPa) to remain within the linear elastic region. Significant variability of individual strain measurements were observed from point couples on the same sample, indicating non-uniform loading did occur in all samples. However, by averaging across multiple points, linear loading profiles were ascertained (fig.2). For all non-contact methods the calculated elastic moduli were found to range between 331–428 MPa whilst the approximated modulus based on cross head displacement was ∼210 MPa, similar to the manufacturer's quoted value (220MPa). The point-tracking gave a significantly higher modulus (p = 0.047) than the DVC results as only surface measurements were made. It is thought that a correction factor may be ascertained from the finite element method to correct this. Both the DVC and point-tracking results (p = 0.001) indicated a substantially higher compressive modulus than the manufacturer provided properties. This study demonstrates that methods of measuring displacement data on cellular foams must be carefully considered, as artefacts can lead to errors of up to 70% compared to optical and x-ray based techniques

Introduction:. Angular mismatch of the modular junction between the head and the trunion has been recognized as a contributing factor to fretting and corrosion of hip prostheses. Excessive angular-mismatch can lead to relative motion at the taper interface, and tribo-corrosion of the head-neck junction secondary to disruption of the passive oxide layer. Although manufacturing standards have been adopted to define acceptable tolerances for taper angles of mating components, recent investigations of failed components have suggested that stricter tolerances or changes in taper design may be necessary to avoid clinical failures secondary to excessive taper wear and corrosion. In this study we examine the effect of angular-mismatch on relative motion between the taper and bore subjected to normal gait load using finite element methods. Methods:. Computer simulations were executed using a verified finite element model (FEM), the results from which were determined to be consistent with literature. A stable, converging hexahedral mesh was defined for the trunnion (33648 elements) and a tetrahedral mesh for the femoral head (51182 elements). A friction-based sliding contact was defined at the taper-bore interface. A gait load of 1638N (2.34 × BW, BW = 700N) was applied at an angle of 30° to the trunnion axis (Figure 1) on an assembled FEM. A linear static solution was set up using Siemens NX-Nastran solver. Angular-mismatch was simulated by incrementing the conical half-angle of the bore to examine these cases: 0°, 0.005°, 0.010°, 0.015°, 0.030°, 0.050°, 0.075°, 0.100°, 0.200°and 0.300°. Results:. Relative interface micro-motion at the proximal-medial point of the taper demonstrated a lack of dependence upon angular-mismatch for tolerances up to 0.075° and a monotonic increase in micro-motion for higher tolerances (0.075–0.3 °; Figure 2). A similar trend was observed with respect to the average values of contact pressure, max von Mises stress and shear stress acting at the proximal-medial aspect of the taper (Figure 3). Non-linear correlation tests indicate a significant correlation (p < 0.0001) of mismatch angle with peak von Mises stress (r = 0.965) and relative micro-motion (r = 0.964). Discussion:. The FEA results corroborate the notion that high angular-mismatch tolerances have a deleterious effect of fretting at the trunnion-head interface. Although, stability of the implant did not appear to be compromised at relatively lower tolerances, the propensity for it is higher at higher mismatches. The simulation was, however, executed as a single-step static analysis ignoring the effect of cyclical loading often observed during gait. This abstract serves as a proof of concept to justify the further development of this FEA to study the effect of angular-mismatch tolerances on micro-motion at the trunnion-head interface. However, current results strongly indicate that tolerance for angular-mismatch can be more liberal without increasing the micro-motion and stresses at the trunnion-head interface. Significance: The effect of angular-mismatch suggests a threshold tolerance different from the industry accepted tolerance of 0.0167°. Mismatches smaller than 0.075° demonstrated only modest variation in the interface micro-motion. Additionally, the results corroborate recent clinical evidence that even with perfectly fit implants, the potential for interface micro-motion can lead to fretting-induced corrosion

INTRODUCTION. Wear and polyethylene damage have been implicated in up to 22% of revision surgeries after unicompartmental knee replacement. Two major design rationales to reduce this rate involve either geometry and/or material strategies. Geometric options involve highly congruent mobile bearings with large contact areas; or moderately conforming fixed bearings to prevent bearing dislocation and reduce back-side wear, while material changes involve use of highly crosslinked polyethylene. This study was designed to determine if a highly crosslinked fixed-bearing design would increase wear resistance. METHODS. Gravimetric wear rates were measured for two unicompartmental implant designs: Oxford unicompartmental (Biomet) and Triathlon X3 PKR (Stryker) on a knee wear simulator (AMTI) using the ISO-recommended standard. The Oxford design had a highly conforming mobile bearing of compression molded Polyethylene (Arcom). The Triathlon PKR had a moderately conforming fixed bearing of sequentially crosslinked Polyethylene (X3). A finite element model of the AMTI wear simulation was constructed to replicate experimental conditions and to compute wear. This approach was validated using experimental results from previous studies. The wear coefficient obtained previously for radiation-sterilized low crosslinked polyethylene was used to predict wear in Oxford components. The wear coefficient obtained for highly crosslinked polyethylene was used to predict wear in Triathlon X3 PKR components. To study the effect design and polyethylene crosslinking, wear rates were computed for each design using both wear coefficients. RESULTS. Wear rates were significantly lower (69%) for the Triathlon fixed-bearing design compared to the Oxford mobile-bearing design (Fig 1, p<0.01). The FEA model predicted 46% of wear occurring at the back side of the mobile bearing (Fig 2). When wear was computed for the Triathlon PKR design using the wear coefficients used for the low crosslinked polyethylene, wear rates increased to 13.9 mg/million cycles. DISCUSSION. We used a combined experimental and computational approach to quantify factors contributing to polyethylene wear after unicompartmental knee arthroplasty. To isolate the effect of crosslinking level and mobile-bearing design, we computed wear rates for both designs using the same wear coefficient obtained for low crosslinked polyethylene. Wear rates in the low crosslinked Triathlon PKR insert increased by more than 160% relative to those in the highly crosslinked Triathlon X3 PKR. The finite element method facilitates computation of relative back-side to front-side wear, which is challenging to obtain experimentally. The back-side wear Oxford mobile bearing was 46% of total wear. Major factors contributing to the difference in wear were back-side wear (46%) and increased crosslinking (63%) with the combined effect having an additive effect. Our FEA-predicted wear penetration rates (0.024 mm/million cycles) also compare well to in vivo studies, which reported penetration rates of 0.022 mm/year for Oxford bearings. A validated computer model is extremely valuable for efficient evaluation of wear performance and design development. In summary, increasing conformity to increase contact area and reduce contact stress may not be the sole predictor of wear performance. A highly crosslinked polyethylene insert in a fixed-bearing design may provide the high wear performance of a mobile-bearing design without the increased risk for bearing dislocation

Introduction. Although total hip arthroplasty (THA) has been one of the most successful, reliable and common prosthetic techniques since the introduction of cemented low-friction arthroplasty by Charnley in the early 1960s, aseptic loosening due to stem-cement and cement-bone interface failures as well as cement fractures have been known to occur. To overcome this loosening, the stem should be mechanically retentive and stable for long term repetitive loading. Migration studies have shown that all stems migrate within their cement mantle, sometimes leading to the stem being debonded from the cement [1]. If we adopt the hypothesis that the stems debond from the cement mantle, the stem surface should be polished. For the polished stem, the concept of a double taper design, which is tapered in the anteroposterior (AP) and mediolateral (ML) planes, and a triple-tapered design, which has trapezoidal cross-section with the double tapered, have been popularized. Both concepts performed equally well clinically [2]. In this study, we aimed to analyze stress patterns for both models in detail using the finite element (FE) method. Methods. An ideal cemented stem with bone was made using three dimensional FE analyses (ANSYS 13). The cortical bone was 105 mm long and 7 mm thick and the PMMA cement mantle was 5 mm in thickness surrounding the stem. Young's modulus was set at 200 GPa for the bone and 2.2 GPa for the cement. Poisson's ratio was 0.3 for both materials. The bone-cement interface was completely bonded and cement-stem interface was not bonded in cases where a polished stem surface was used. The two types of stems were compared. One being the double tapered (Fig 1 left) and the other the triple tapered (Fig 1 right). The coefficient of friction (μ) at the stem-cement interface was set at 0 for both models. The distal ends of the stems were not capsulated by the PMMA and therefore the stems were free to subside. All materials were assumed to be linearly isotropic and homogeneous. The distal ends of the bone were completely constrained against any movements and rotations. An axial load of 1200 N and a transverse load of 600 N were applied at the same time simulating the bending condition [3]. Results. Although the stress distribution differences between the designs were minor, the positions where higher stresses and absolute values in the cement were observed varied. For double tapered model, the highest maximum principal stress was 1.98 MPa observed around the corner of the stem at the proximal region. For the triple tapered model, the highest maximum principal stress was 1.67 MPa observed at more medial side than the double tapered model

Representative pre-clinical analysis is essential to ensure that novel prosthesis concepts offer an improvement over the state-of-the-art. Proposed designs must, fundamentally, be assessed against cyclic loads representing common daily activities [Bergmann 2001] to ensure that they will withstand conceivable in-vivo loading conditions. Fatigue assessment involves:. –. cyclic mechanical testing, representing worst-case peak loads encountered in-vivo, typically for 10 million cycles, or. –. prediction of peak fatigue stresses using Finite Element (FE) methods, and comparison with the material's endurance limit. Cyclic stresses from gait loading are super-imposed upon residual assembly stresses. In thick walled devices, the residual component is small in comparison to the cyclic component, but in thin section, bone preserving devices, residual assembly stresses may be a multiple of the cyclic stresses, so a different approach to fatigue assessment is required. Modular devices provide intraoperative flexibility with minimal inventories. Components are assembled in surgery with taper interfaces, but resulting residual stresses are variable due to differing assembly forces and potential misalignment or interface contamination. Incorrect assembly can lead to incomplete seating and dissociation [Langdown 2007], or fracture due to excessive press-fit stress or point loading [Hamilton 2010]. Pre-assembly in clean conditions, with reproducible force and alignment, gives close control of assembly stresses. Clinical results indicate that this is only a concern with thick sectioned devices in a small percentage of cases [Hamilton 2010], but it may be critical for thin walled devices. A pre-clinical analysis method is proposed for this new scenario, with a case study example: a thin modular cup featuring a ceramic bearing insert and a Ti-6Al-4V shell (Fig. 1). The design was assessed using FE predictions, and manufacturing variability from tolerances, surface finish effects and residual stresses was assessed, in addition to loading variability, to ensure physical testing is performed at worst case:. –. assembly loads were applied, predicting assembly residual stress, verified by strain gauging, and a range of service loads were superimposed. The predicted worst-case stress conditions were analysed against three ‘constant life’ limits [Gerber, 1874, Goodman 1899, Soderberg 1930], a common aerospace approach, giving predicted safety factors. Finally, equivalent fatigue tests were conducted on ten prototype implants. Taking a worst-case size (thinnest-walled 48 mm inner/58 mm outer), under assembly loading the peak tensile stress in the titanium shell was 274 MPa (Fig. 2). With 5kN superimposed jogging loading, at an extreme 75° inclination, 29 MPa additional tensile stress was predicted. This gave mean fatigue stress of 288.5 MPa and stress amplitude of 14.5 MPa (R=0.9). Against the most conservative infinite life limit (Soderberg), the predicted safety factor was 2.40 for machined material, and 2.03 for forged material, or if a stress-concentrating surface scratch occurs during manufacturing or implantation (Fig. 3). All cups survived 10,000,000 fatigue cycles. This study employed computational modelling and physical testing to verify the strength of a joint prosthesis concept, under worst case static and fatigue loading conditions. The analysis technique represents an improvement in the state of the art where testing standards refer to conventional prostheses; similar methods could be applied to a wide range of novel prosthesis designs