Polyethylene wear in total knee arthroplasty (TKA) is a complex and mutifactorial process. It is generally recognized that wear is directly related to a material wear factor, contact stress, and sliding distance. Conventional methods of predicting polyethylene wear in TKA mainly focus on peak contact stress or subsurface shear stress using finite element method analysis. By incorporating kinematics and contact stress, a new predictor for polyethylene wear in TKA (“Wear Index”) has been developed. The Wear Index was defined by multiplying deformation by femoro-tibial sliding velocity. The purpose of this study was to determine the predictive value of the Wear Index for polyethylene wear in TKA using both a numeric and an in vitro model.

Four commercially available total knee prostheses were modeled for this study. Deformation and sliding velocity were calculated based on the three-dimensional geometry of the components and the gait kinematic inputs using Hertz’s formula. One specimen of each of the four types of total knee prostheses was mounted on a custom-designed knee simulator. Vertical loads and flexion-extension uni-axial motion were simulated using computer controlled servohydraulic actuators. The same gait kinematic inputs used in the theoretical study were used in the simulation test. After the simulations, the surface of the tibial insert was examined microscopically and macroscopically and compared with the theoretically generated Wear Index.

This study showed a high correlation between the numeric model and the simulation. The depth of wear on the tibial insert correlated significantly with the Wear Index. Microscopic findings also demonstrated a good correlation between the Wear Index and observed wear patterns. Sliding velocity is an important factor for understanding wear in TKA. In conclusion, this study suggests that the Wear Index is a reliable predictor of polyethylene wear in TKA, as it incorporates both contact stress and kinematics in its calculation.