Finite element wear prediction using adaptive meshing at the modular taper interface of hip implants

Stability Analysis of Plate-Screw Fixation for Femoral Midshaft Fractures

An understanding of the biomechanical characteristics and configuration of flexible and locked plating in order to provide balance stability and flexibility of implant fixation will help to construct and promote fast bone healing. The relationship between applied loading and implantation configuration for best bone healing is still under debate. This study aims to investigate the relationship between implant strength, working length, and interfragmentary strain (εIFM) on implant stability for femoral midshaft transverse fractures. The transverse fracture was fixed with a fragment locking compression plate (LCP) system. Finite element analysis was performed and subsequently characterised based on compression loading (600 N up to 900 N) and screw designs (conventional and locking) with different penetration depths (unicortical and bicortical). Strain theory was used to evaluate the stability of the model. The correlation of screw configuration with screw type shows a unicortical depth for both types (p < 0.01) for 700 N and 800 N loads and (p < 0.05) for configurations 134 and 124. Interfragmentary strain affected only the 600 N load (p < 0.01) for the bicortical conventional type (group BC), and the screw configurations that were influenced were 1234 and 123 (p < 0.05). The low steepness of the slope indicates the least εIFM for the corresponding biomechanical characteristic in good-quality stability. A strain value of ≤2% promotes callus formation and is classified as absolute stability, which is the minimum required value for the induction of callus and the maximum value that allows bony bridging. The outcomes have provided the correlation of screw configuration in femoral midshaft transverse fracture implantation which is important to promote essential primary stability.

Finite Element Analysis for Pre-Clinical Testing of Custom-Made Knee Implants for Complex Reconstruction Surgery

In severe cases of total knee arthroplasty, where off-the-shelf implants are not suitable or available anymore (i.e., in cases with extended bone defects or periprosthetic fractures), custom-made knee implants represent one of the few remaining treatment options. Design verification and validation of such custom-made implants is very challenging. The aim of this study is to support surgeons and engineers in their decision on whether a developed design is suitable for the specific case. A novel method for the pre-clinical testing of custom-made knee implants is suggested, which relies on the biomechanical test and finite element analysis (FEA) of a comparable reference implant. The method comprises six steps: (1) identification of the main potential failure mechanism and its corresponding FEA quantity of interest, (2) reproduction of the biomechanical test of the reference implant via FEA, (3) identification of the maximum value of the corresponding FEA quantity of interest at the required load level, (4) definition of this value as the acceptance criterion for the FEA of the custom-made implant, (5) reproduction of the biomechanical test with the custom-made implant via FEA, (6) conclusion, whether the acceptance criterion is fulfilled or not. Two exemplary cases of custom-made knee implants were evaluated with this method. The FEA acceptance criterion derived from the reference implants was fulfilled in both custom-made implants. Subsequent biomechanical tests verified the FEA results. The suggested method allows a quantitative evaluation of the biomechanical properties of a custom-made knee implant without performing a biomechanical test with it. This represents an important contribution in the pre-clinical testing of custom-made implants in order to achieve a sustainable treatment of complex revision total knee arthroplasty patients in a timely manner.

Finite element analysis of a hybrid corrugated hip implant for stability and loading during gait phases

Implants used in total hip replacements (THR) exhibit high failure rates and up to a decade of operational life. These surgical failures could be mainly attributed to the improper positioning, post-surgical stability and loading, of the implants during different phases of the gait. Typically, revised surgeries are suggested within a few years of hip implantation, which requires multiple femoral drilling operations to remove an existing implant, and to install a new implant. The pain and trauma associated with such procedures are also challenging with the existing hip implants. In this work, we designed a novel corrugated hip implant with innovative dimensioning as per ASTM standards, and grooves for directed insertion and removal (using a single femoral drilling and positioning operation). Biocompatible titanium alloy (Ti6Al4V) was chosen as the implant material, and the novel implant was placed into a femur model through a virtual surgery to study its stability and loading during a dynamic gait cycle. A detailed mesh convergence study was conducted to select a computationally accurate finite element (FE) mesh. Tight fit and frictional fit attachment conditions were simulated, and the gait induced displacements and stresses on the implant, cortical and cancellous bone sections were characterized. During walking, the implant encountered the maximum von-Mises stress of 254.97 MPa at the femoral head. The analyses indicated low micro-motions (i.e., approximately 7μm) between the femur and implant, low stresses at the implant and bone within elastic limits, and uniform stress distribution, which unlike existing hip implants, would be indispensable for bone growth and implant stability enhancement, and also for reducing implant wear.

Strain Analysis in Cementless Hip Femoral Prosthesis using the Finite Element Method - Influence of the Variability of the Angular Positioning of the Implant

Objective  The present study aims to evaluate the influence of different positioning of the hip femoral prosthesis on the stress and strain over this implant. Methods  A femoral prosthesis (Taper - Víncula, Rio Claro, SP, Brazil) was submitted to a stress and strain analysis using the finite element method (FEM) according to the International Organization for Standardization (ISO) 7206-6 Implants for surgery - Partial and total hip joint prostheses - Part 6: Endurance properties testing and performance requirements of neck region of stemmed femoral components standard. The analysis proposed a branch of the physical test with a +/- 5° angle variation on the standard proposed for α and β variables. Results  The isolated +/- 5° variation on the α angle, as well as the association of +/- 5° variation on the α and β angles, presented significant statistical differences compared with the control strain ( p  = 0.027 and 0.021, respectively). Variation on angle β alone did not result in a significant change in the strain of the prosthesis ( p  = 0.128). The stem positioning with greatest implant strain was α = 5° and β = 14° ( p  = 0.032). Conclusion  A variation on the positioning of the prosthetic femoral stem by +/- 5° in the coronal plane and/or the association of a +/- 5° angle in coronal and sagittal planes significantly influenced implant strain.

Delamination-fretting wear failure evaluation at HAp-Ti-6Al-4V interface of uncemented artificial hip implant

Present research aims to develop a finite element computational model to examine delamination-fretting wear behaviour that can suitably mimic actual loading conditions at HAp-Ti-6Al-4V interface of uncemented hip implant femoral stem component. A simple finite element contact configuration model based on fretting fatigue experimental arrangement subjected to different mechanical and tribological properties consist of contact pad (bone), HAp coating and Ti-6Al-4V substrate are developed using adaptive wear modelling approach adopting modified Archard wear equation to be examined under static simulation. The developed finite element model is validated and verified with reported literatures. The findings revealed that significant delamination-fretting wear is recorded at contact edge (leading edge) as a result of substantial contact pressure and contact slip driven by stress singularity effect. The delamination-fretting wear behaviour is promoted under higher delamination length, lower normal loading with higher fatigue loading, increased porous (cancellous) and cortical bone elastic modulus with higher cycle number due to significant relative slip amplitude as the result of reduced interface rigidity. Tensile-compressive condition (R=-1) experiences most significant delamination-fretting wear behaviour (8 times higher) compared to stress ratio R=0.1 and R=10.

The mechanics of head-neck taper junctions: What do we know from finite element analysis?

Modular hip implants are widely used in hip arthroplasty because of the advantages they can offer such as flexibility in material combinations and geometrical adjustments. The mechanical environment of the modular junction in the body is quite challenging due to the complex and varying off-axial mechanical loads of physical activities applied to a tapered interface of two contacting materials (head and neck) assembled by an impact force intraoperatively. Experimental analogies to the in-vivo condition of the taper junction are complex, expensive and time-consuming to implement; hence, computational simulations have been a preferred approach taken by researchers for studying the mechanics of these modular junctions that can help us understand their failure mechanisms and improve their design and longevity after implantation. This paper provides a clearer insight into the mechanics of the head-neck taper junction through a careful review on the finite element studies of the junction and their findings. The effects of various factors on the mechanical outputs namely: stresses, micromotions, and contact situations are reviewed and discussed. Also, the simulation methodology of the studies in the literature is compared. Research opportunities for future are scrutinised through tabulating data and information that have been carefully retrieved form the reported findings.

A review on the finite element simulation of fretting wear and corrosion in the taper junction of hip replacement implants

Taperosis/trunnionosis is a scientific term for describing tribocorrosion (fretting corrosion) at the head-neck taper junction of hip implants where two contacting surfaces are undergone oscillatory micromotions while being exposed to the body fluid. Detached ions and emitted debris, as a result of taperosis, migrate to the surrounding tissues and can cause inflammation, infection, and aseptic loosening with an ultimate possibility of implant failure. Improving the tribocorrosion performance of the head-neck junction in the light of minimising the surface damage and debris requires a better understanding of taperosis. Given its complexity associated with both the mechanical and electrochemical aspects, computational methods such as the finite element method have been recently employed for analysing fretting wear and corrosion in the taper junction. To date, there have been more efforts on the fretting wear simulation when compared with corrosion. This is because of the mechanical nature of fretting wear which is probably more straightforward for modelling. However, as a recent research advancement, corrosion has been a focus to be implemented in the finite element modelling of taper junctions. This paper aims to review finite element studies related to taperosis in the head-neck junction to provide a detailed understanding of the design parameters and their role in this failure mechanism. It also reviews and discusses the methodologies developed for simulating this complex process in the taper junction along with the simplifications, assumptions and findings reported in these studies. The current needs and future research opportunities and directions in this field are then identified and presented.

Specimen-Specific Finite Element Models for Predicting Fretting Wear in Total Hip Arthroplasty Tapers

Products from fretting wear and corrosion in the taper junction of total hip arthroplasty (THA) devices can lead to adverse local tissue reactions. Predicting damage as a function of design parameters would aid in the development of more robust devices. The objectives of this study were to develop an automated method for identifying areas of fretting wear on THA taper junctions, and to assess the predictive ability of a finite element model to simulate fretting wear in THA taper junctions. THA constructs were fatigue loaded, thus inducing damage on the stem taper. An automated imaging and analysis algorithm quantified fretting wear on the taper surfaces. Specimen-specific finite element models were used to calculate fretting work done (FWD) at the taper junction. Simulated FWD was correlated to imaged fretting wear. Results showed that the automated imaging approach identified fretting wear on the taper surface. Additionally, finite element models showed the greatest predictive ability for tapers exhibiting distal contact. Finite element models predicted an average of 30.3% of imaged fretting wear. With additional validation, the imaging and finite element techniques may be useful to manufacturers and regulators in the development and review of new THA devices.

Contact conditions for total hip head-neck modular taper junctions with microgrooved stem tapers

Implant failure due to fretting-corrosion of head-neck modular junctions is a rising problem in total hip arthroplasty. Fretting-corrosion initiates when micromotion leads to metal release; however, factors leading to micromotion, such as microgrooves on the stem taper, are not fully understood. The purpose of this study is to describe a finite element analysis technique to determine head-neck contact mechanics and investigate the effect of stem taper microgroove height during head-neck assembly. Two-dimensional axisymmetric finite element models were created. Models were created for a ceramic femoral head and a CoCrMo femoral head against Ti6Al4V stem tapers and compared to available data from prior experiments. Stem taper microgroove height was investigated with a generic 12/14 model. Head-neck assembly was performed to four maximum loads (500 N, 2000 N, 4000 N, 8000 N). For the stem taper coupled with the ceramic head, the number of microgrooves in contact and plastically deformed differed by 2.5 microgrooves (4%) and 6.5 microgrooves (11%), respectively, between the finite element models and experiment. For the stem taper coupled with the CoCrMo head, all microgrooves were in contact after all assembly loads in the finite element model due to an almost identical conical angle between the taper surfaces. In the experiments, all grooves were only in contact for the 8000 N assembly load. Contact area, plastic (permanent) deformation, and contact pressure increased with increasing assembly loads and deeper microgrooves. The described modeling technique can be used to investigate the relationship between implant design factors, allowing for optimal microgroove design within material couples.