Angular mismatch between the head and trunnion is recognized as a contributing factor to mechanically-assisted corrosion of modular hip prostheses. Although manufacturing standards have been adopted to define acceptable tolerances for taper angles of mating components, the relationship between the head and trunnion taper angles (positive or negative) differs between manufacturers. In this study, we investigated the effect of positive and negative angular mismatch on the interface mechanics of a standard design of taper junction using finite element analysis (FEA). Computer simulations were executed using an FE model which had been previously verified through direct comparison with experimental studies. The neck and trunnion of a Ti6Al4V femoral component (taper size: 12/14mm) were modelled using a stable hexahedral mesh (33,648 elements), while the femoral head (CoCrMo, size: 32mm) was modelled using a tetrahedral mesh (51,182 elements). Assembly of the head on the trunnion was simulated through the application of a load of 4000N along the trunnion axis. This was followed by the application of a gait load of 1638N (2.34×700N BW) at an angle of 30o to the trunnion axis. A friction-based sliding interface (mu=0.12) was simulated at the trunnion-head junction. A linear static solution was set up using Siemens NX Nastran. In addition to a perfect match, 7 positive and negative mismatch angles were simulated ranging from −0.100 to 0.100 degrees. Head taper interface motion, contact pressure and internal stresses (von Mises) were calculated for each mating condition.Introduction
Methods
Relative motion at the modular head-neck junction of hip prostheses can lead to severe surface damage through mechanically-assisted corrosion. One factor affecting the mechanical performance of modular junctions is the frictional resistance of the mating surfaces to relative motion. Low friction increasing forces normal to the head-neck interface, leading to a lower threshold for slipping during weight-bearing. Conversely, a high friction coefficient is expected to limit interface stresses but may also allow uncoupling of the interface in service. This study was performed to examine this trade-off using finite element models of the modular head-neck junction A finite element model (FEM) of the trunnion/ head assembly of a total hip prosthesis was initially created and experimentally validated. CAD models of a stem trunnion (taper size: 12/14mm) and a prosthetic femoral head (diameter: 28mm) were discretized into elements for finite element analysis (FEA). The trunnion (Ti6Al4V) was modelled with a hexahedral mesh (33,648 elements) and the femoral head (CoCrMo) with a tetrahedral mesh (51,182 elements). A friction-based sliding contact interface was defined between the mating surfaces. The model was loaded in 2 stages: (i) an assembly load of 4000N applied along the trunnion axis, and (ii) 500N applied along the trunnion axis in combination with a torque of 10Nm. A linear static solution was set up using Siemens NX-Nastran solver. Multiple simulations were executed by modulating the frictional coefficient at the taper-bore interface from 0.05 to 0.15 in increments of 0.01, the coefficient of 0.1 serving as the control case (Swaminathan and Gilbert, 2012).Introduction
Methods
Recent retrieval studies and registry reports have demonstrated an alarming incidence of early failure of metal-on-metal THR. This appears to be due to fretting and corrosion at the taper junction (trunnion) between the neck and large diameter heads in metal-on-metal hip implants. It has been proposed that designs with lower bearing clearances and greater cup flexibility deform during implantation leading to increased frictional torque and micromotion at the head-neck taper junction. Small movements at the trunnion may suggest elastic deformation, but large movements may suggest slippage at the friction interface. This study was conducted using retrieved metal-on-metal components to test the hypotheses that: 1. Cup deformation through localized compression leads to increased bearing torque, and 2. Increased torques generated in large head metal-on-metal bearings cause motion of the head-neck taper junction. Nine metal-on-metal hip implants were received from a national joint retrieval service and tested in a mechanical testing machine. The components were of three different designs (ASR, BHR, and Durom) and ranged in diameter from 42–54 mm. A custom jig was constructed to generate controlled radial compression at opposite points on the rim of an acetabular component. The jig was positioned inverted to the normal anatomical position and was angled to simulate the anatomical orientation of the cup (35° inclination, 10° anteversion). With the exception of an initial compression load of 100N, the cups were compressed at 200N intervals to a maximum of 2000N. Three trials at each cup compression load were performed. The torque developed about the trunnion axis was measured as the head articulated through a motion arc of 60° and the friction factor was calculated. Head–neck micromotion was continuously monitored using a non-displacement inductive transducer. Changes in micromotion from the 100N compression load were calculated.Introduction
Materials and Methods
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. 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°.Introduction:
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Femoro-acetabular impingement reduces the range of motion of the hip joint and is thought to contribute to hip osteoarthritis. Surgical treatments attempt to restore hip motion through resection of bone at the head-neck junction. Due to the broad range of morphologies of FAI, the methodology of osteochondroplasty has been difficult to standardize and often results in unexpected outcomes, ranging from minimal improvement in ROM to excessive head resection with loss of cartilage and even neck fracture. In this study we test whether a standardized surgical plan based on a pre-determined resection path can restore normal anatomy and ROM to the CAM-impinging hip. Computer models of twelve femora with classic signs of cam-type FAI were reconstructed from CT scans. The femoral shaft and neck were defined with longitudinal axes and the femoral head by a sphere of best fit. Boundaries defining the maximum extent of anterior resection were constructed: (i) superiorly and inferiorly along the anterior femoral neck at 12:30 and 5:30 on the clock face, approximating the locations of the vascularized synovial folds; (ii) around the head-neck junction along the edge of the articular cartilage; and (iii) at the base of the neck, perpendicular to the neck axis, 20–30 mm lateral to the articular edge. All four boundaries were used to form 3 alternative resection surfaces that provided resection depths of 2 mm (small), 4 mm (medium), and 6 mm (large) at the location of the cam lesion. Solid models of each femur after virtual osteochondroplasty were created by Boolean subtraction of each of the resection surfaces from the original femoral model. For each depth of neck resection, we measured the following: (i) alpha angle, (ii) anterior offset of the head-neck junction, and (iii) volume of bone removed. Before and after each resection, we also measured the maximum internal rotation of the hip in 90° flexion and 0° abduction.Introduction:
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A disturbing prevalence of painful inflammatory reactions has been reported in metal-on-metal (MoM) hip resurfacing arthroplasty. A contributing factor is localized loading of the acetabular shell leading to “edge wear” which is often seen after precise measurement of the bearing surfaces of retrieved components. Factors contributing to edge wear include adverse cup orientation leading to proximity (<10 mm) of the hip reaction force to the edge of the acetabular component. As this phenomenon is a function of implant positioning and patient posture, this study was performed to investigate the occurrence of edge loading during different functional activities as a function of cup inclination and version. We developed a computer model of the hip joint through reconstruction of CT scans of a proto-typical pelvis and femur and virtually implanting a hip resurfacing prosthesis in an ideal position. Using this model, we examined the relationship between the resultant hip force vector and the edge of the acetabular shell during walking, stair ascent and descent, and getting in and out of a chair. Load data was derived from 5 THR patients implanted with instrumented hip prostheses (Bergmann et al). We calculated the distance from the edge of the shell to the point of intersection of the load vector and the bearing surface for cup orientations ranging from 40 to 70 degrees of inclination, and 0 to 40 degrees of anteversion.Introduction:
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It has been speculated that impact deformation of thin 1-piece cups used for modern metal-on-metal hip replacement may contribute to early failure. The purpose of this study was to reproduce typical impact deformation and quantify the effect of this on the frictional torque generated at the hip. We tested nine hip couples of three designs (the ASR, BHR and Durom) and three sizes (42mm, 46mm and 50mm). A custom compression device was designed to replicate the in vivo forces and impact deformation of 1-piece metal cups reported in the literature. Each cup was mounted in the device, which itself was mounted on a mechanical testing machine. The cups were compressed with incremental loads up to a maximum of 2000N. At each increment we measured cup deformation, and then the head component was seated into the cup. The hip was lubricated and the head component rotated 60 degrees axially within the cup and the axial torque was measured.Introduction
Methods
