Fluid film lubricating ability of a total hip prosthesis depends on the profile accuracies including surface-roughness or the sphericity of a head or a cup. Therefore, surface polishing is important. It was, however, difficult to polish the central portion of a cup or head using the conventional rotating machine. In the present study, we developed a polishing method combining a pendulum machine and a robotic arm. The effect of the accuracy improvement by this method was evaluated by the friction measurements on some test specimens. Nine balls and a cup of Co-Cr-Mo alloy that were polished by a conventional process using a rotating machine were prepared for the prototype. The average diameter of the balls was 31.9648 mm with the sphericity of 0.0028 μm. The inside diameter of the cup was 31.9850 mm with the sphericity of 0.0044 μm. We combined a robotic arm and a pendulum apparatus to enable the further polishing. The ability of both automatic centering and change in the sliding direction was accomplished by this system. The sliding direction has been changed 180 times every ten degrees. The total distance of polishing was 120 m under vertical load of 100 N in a bath of saline solution containing abrasive grains of silicate of the diameter of 2μm. The surface roughness of the central portion of the cup, which is important area for the fluid film lubrication decreased from Ra 20.2 μm before the polishing to Ra 18.7 μm after the polishing. A pendulum type friction tester was used for the assessment of the improvement of the lubricating ability by the polishing. The measurement was run over at 10 times under the conditions of the load of 600 N in a bath of saline solution. As the result, the frictional coefficients decreased from 0.1456–0.1720 before polishing to 0.1250–0.1300 after polishing. The polishing effect was, however, observed only at the specimens that radial clearances did not exceed the value of 50 μm. The present results indicated that the surface polishing of the central portion of hip prostheses must improve the lubrication ability and the radial clearance before the finishing process should be chinked as possible

1. Introduction. Metal-on-metal (MOM) hip joints have regained a favor in arthroplasty since they own excellent wear resistance. In this study, wear tests by using a hip joint simulator were conducted with MOM bearings of specified 40 mm femoral heads. The influence of clearance on the wear behavior was investigated. Furthermore, an optimized radial clearance was estimated by lubricant film thickness and contact pressure analysis. 2. Materials and methods. Co-27Cr-5Mo-0.13N-0.05C (hereafter CCMN) alloy (mass %) was used. The ingots were vacuum induction melted, homogenized and hot forged successively. The microstructure shows equiaxed crystal grains with abundant annealing twins but no carbides. Two groups of bearings, indicated as cr 1 and cr 2, were designed. The radial clearances for cr 1 and cr 2 were 37.9 and 148.7 μm, respectively. Wear tests were conducted in a hip joint simulator (INSTRON 8870) in Hanks' solution at 37±2°f. The force and 3-axile angle of movement were applied on the articulation according to ISO 14242-1 for 1.5 million cycles (Mc). The contact pressures on the hip joints were also analyzed by using ABAQUS. The femoral heads were set 40 mm with radial clearances of 0–200 μm. Half models were set up and only the maximum force of 3 kN converted as pressure was applied as boundary condition. 3. Results and discussion. In general, the wear scratches paralleling to the flexion-extension direction tend to the greatest [Fig. 1]. For cr 1, shallow scratches and few plowing-grooves were observed. While for cr 2, deep plowing-grooves (5–10 μm) with obvious plastic deformation were generated in large quantities by abrasive wear. The wear rate [Fig. 2] for cr 2 was approximately 29.5 mm. 3. /Mc more than the one for cr 1, probable caused by different lubrication mode and contact pressure for different clearances. From the prediction of the lubricant film thickness, the lubrication regime transformed from full film lubrication to boundary lubrication for cr 1 and mixed film lubrication to boundary lubrication for cr 2. The simulation results [Fig. 3] also show that as the clearance increase, the contact pressure would increase leading to aggravating wear. On the other hand, if the clearance is too small, the contact pressure also increases by wedging and equatorial contact of the articulation. For a MOM articulation with a 40 mm femoral head, there is a minimum contact pressure when the radial clearance is between 40 and 50 μm. 4. Conclusions. To summarize, for a 40 mm diameter MOM articulation, abrasive wear was the dominant wear mechanism. The wear decreased as the radial clearance decreased, due to a thicker lubricant film thickness which can separate the surfaces' direct contact. However, the function of the contact pressure and radial clearance was not monotonous. It could be concluded that an optimized radial clearance ranging in 40–50 μm is appropriate for this MOM hip joint

Introduction. Large diameter femoral heads provide increased range-of-motion and reduced dislocation rates compared to smaller diameter femoral heads. However, several recent studies have reported that contemporary large head prostheses can directly impinge against the local soft tissues leading to anterior hip pain. To address this we developed a novel Anatomically Contoured large diameter femoral Head (ACH) that maintains the profile of a large diameter femoral head over a hemispherical portion and then contours inward the distal profile of the head for soft-tissue relief. We hypothesized that the distal contouring of the ACH articular surface would not affect contact area. The impact of component placement, femoral head to acetabular liner radial clearance, and joint loading during different activities was investigated. Methods. A finite element model was used to assess the femoroacetabular contact area of a 36 mm diameter conventional head and a 36 mm ACH (Fig. 1). It included a rigid acetabular shell, plastically deformable UHMWPE acetabular liner, rigid femoral head and rigid femoral stem. The femoral stem was placed at 0°, 10° and 20° of anteversion. The acetabular shell and liner were placed in 20°, 40° and 60° of abduction and 0°, 20° and 40° of anteversion. The femoral head to acetabular liner radial clearances modeled were 0.06 mm, 0.13 mm and 0.5 mm. Three loading cases corresponding to peak in vivo loads during walking, chair sit and deep-knee bend were analyzed (Fig. 2). This allowed a range of component positions and maximum joint loads to be studied. Results. Under all tested conditions there was no difference between the two implants (Fig. 3). The contact area for both prosthesis depended on the radial clearance between the head and liner. The conventional head contact area (standard deviation) in mm. 2. for 0.5 mm, 0.13 mm and 0.06 mm of radial clearance was 230.5 (70.2), 419.8 (48.7) and 575.4 (60.1) respectively. Similarly, for the ACH these were 230.5 (70.4), 420.1 (48.7) and 575.9 (59.4). The average data for a head and radial clearance combination included all component placements and load conditions completed. A student T-Test (p = 0.05) confirmed that the ACH had the same contact area as the conventional head for all radial clearances. Conclusion. This study showed that, as intended, an anatomically contoured large diameter femoral head designed to provide soft-tissue relief maintained the load bearing articular contact area of a conventional implant. The novel ACH prosthesis could mitigate the risk of soft-tissue impingement with contemporary large head implants while retaining their benefits of additional stability and range-of-motion

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. One of the known mechanisms which could contribute to the failure of total hip replacements (THR) is edge contact. Failures associated with edge contact include rim damage and lysis due to altered loading and torques. Recent study on four THR patients showed that the inclusion of pelvic motions in a contact model increased the risk of edge contact in some patients. The aim of current study was to determine whether pelvic motions have the same effect on contact location for a larger patient cohort and determine the contribution of each of the pelvic rotations to this effect. Methods. Gait data was acquired from five male and five female unilateral THR patients using a ten camera Vicon system (Oxford Metrics, UK) interfaced with twin force plates (AMTI) and using a CAST marker set. All patients had good surgical outcomes, confirmed by patient-reported outcomes and were considered well-functioning, based on elective walking speed. Joint contact forces and pelvic motions were obtained from the AnyBody modelling system (AnyBody Technologies, DK). Only gait cycle regions with available force plate data were considered. A finite element model of a 32mm head on a featureless hemispherical polyethylene cup, 0.5mm radial clearance, was used to obtain the contact area from the contact force. A bespoke computational tool was used to analyse patients' gait profiles with and without pelvic motions. The risk of edge contact was measured as a “centre proximity angle” between the cup pole and centre of the contact area, and “edge proximity angle” between the cup pole and the furthest contact area point away from the pole. Pelvic tilt, drop and internal-external rotation were considered one at a time and in combinations. Results. In eight out of 10 patients, the addition of pelvic motions decreased the risk of edge contact during toe-off. There was up to 6° reduction in the proximity angles when pelvic motions were introduced to the gait cycle. In six out of 10 patients, the addition of pelvic motions resulted in an increase in the risk of edge contact during heel-strike with up to 6° increase in the proximity angles. For all patients where these effects were seen, sagittal pelvic tilt was a substantial contributor. Conclusion. The results of this study suggest that pelvic motion play an important role in contact location in THR bearings during loading phase. Both static and dynamic pelvic tilt contribute to the variability in the risk of edge contact. Further tests on larger patient cohorts are required to confirm the trends observed. The outcomes of this study suggest that pre-clinical mechanical and tribological testing of THRs should consider the role of pelvic motion. The outcomes also have implications for establishing surgical positioning safe zones, which are currently based only on risk of dislocation and severe impingement

Background. Complications of metal-on-metal hip resurfacing, leading to implant failure, include femoral notching, neck fracture, and avascular necrosis. Revision arthroplasty options include femoral-only revision with a head, however mis-matching radial clearance could accelerate metal ion release. Alternatively, revision of a well-fixed acetabular component could lead to further bone loss, complicating revision surgery. We have developed a ceramic hip resurfacing system with a titanium-ceramic taper junction; taking advantage of the low frictional torque and wear rates that ceramic affords. Taking a revision scenario into account, the ceramic head has a deep female taper for the resurfacing stem, but also a superficial tapered rim. Should revision to this resurfacing be required, any femoral stem with a 12/14 taper can be implanted, onto which a dual taper adaptor is attached. The outer diameter of the taper adaptor then becomes the male taper for the superficial taper of the ceramic head; ultimately allowing retention of the acetabular component. In an in-vitro model, we have compared the fretting corrosion of this taper adaptor to existing revision taper options: a titanium-cobalt chrome (Ti-CoCr) taper junction, and a titanium-titanium sleeve-ceramic (Ti-Ti-Cer) taper junction. Methods. To simulate gait, sinusoidal cyclical loads between 300N-2300N, at a frequency of 3Hz was applied to different neck offsets generating different bending moments and torques. Bending moment and frictional torque were tested separately. An electrochemical assessment using potentiostatic tests at an applied potential of 200mV, was used to measure the fretting current (μA) and current amplitude (μA). In a short term 1000 cycle test with bending moment, four neck lengths (short to x-long) were applied. For frictional torque, four increments of increasing torque (2-4-6-8Nm) were applied. In a long-term test using the taper adaptor, the combination of worst-case scenario of bending and torque were applied, and fretting currents measured every million cycles, up to 10 million cycles. Results. Short-term test: When adjusting bending moment the taper adaptor displayed equivalent fretting currents for the short and medium neck lengths. Using the long neck the taper adaptor displayed a higher fretting current, though this was not significant (Kruskal-Wallis test). However, using the X-Long adaptor the fretting current was significantly higher than the other tapers (Fig. 1). Across the range of frictional torques, the taper adaptor displayed equivalent fretting currents to the Ti-CoCr single taper. The Ti-Ti-Cer displayed the lowest fretting currents but this was not significant when compared to the other combinations (Fig. 2). Long-term test: combining the worst case bending (X-Long) and torque (8Nm) showed consistent fretting currents and current amplitudes across 10 million cycles, with no significant variance of the median values (Fig. 3). Conclusion. Electro-chemical testing has highlighted caution if revision arthroplasty is performed using the X-Long taper adaptor. However for shorter neck lengths, fretting corrosion is comparable to existing revision tapers. The LIMA ceramic resurfacing arthroplasty is an integrated system and can be safely revised to a conventional hip system using a dual taper head, and taper adaptor

Background. High cup abduction angles generate increased contact stresses, higher wear rates and increased revision rates. However, there is no reported study about the influence of cup abduction on stresses under head lateralisation conditions for ceramic-on-Ceramic THA. Material and method. A finite elements model of a ceramic-on-ceramic THA was developed in order to predict the contact area and the contact pressure, first under an ideal regime and then under lateralised conditions. A 32 mm head diameter with a 30 microns radial clearance was used. The cup was positioned with a 0°anteversion angle and the abduction angle was varied from 45° to 90°. The medial-lateral lateralisation was varied from 0 to 500 microns. A load of 2500 N was applied through the head center. Results. For 45° abduction angle, edge loading appeared above a medial-lateral separation of 30 μm. Complete edge loading was obtained above 60 μm medial-lateral separation. For 45 degrees inclination angle, as the lateralisation increased, the maximal contact pressure increased from 66 MPa and converged to an asymptotic value of 205 MPa. A higher inclination angle resulted in a higher maximum contact pressure. However, this increase in contact pressure induced by higher inclination angle, became negligible as the lateral separation increased. Discussion Both inclination angle and lateral displacement induced a large increase in the stresses in Ceramic-on-Ceramic THA. Edge loading appeared for a small lateralisation. The influence of acetabular inclination angle became negligible for a lateral displacement above 240 μm, as the stresses reached an asymptotic value