Analysis of contact mechanics in ceramic-on-ceramic hip joint replacements

Investigation of contact behavior on a model of the dual-mobility artificial hip joint for Asians in different inner liner thicknesses

BACKGROUND

The four components that make up the current dual-mobility artificial hip joint design are the femoral head, the inner liner, the outer liner as a metal cover to prevent wear, and the acetabular cup. The acetabular cup and the outer liner were constructed of 316L stainless steel. At the same time, the inner liner was made of ultra-high-molecular-weight polyethylene (UHMWPE). As this new dual-mobility artificial hip joint has not been researched extensively, more tribological research is needed to predict wear. The thickness of the inner liner is a significant component to consider when calculating the contact pressure.

AIM

To make use of finite element analysis to gain a better understanding of the contact behavior in various inner liner thicknesses on a new model of a dual-mobility artificial hip joint, with the ultimate objective of determining the inner liner thickness that was most suitable for this particular type of dual-mobility artificial hip joint.

METHODS

In this study, the size of the femoral head was compared between two diameters (28 mm and 36 mm) and eight inner liner thicknesses ranging from 5 mm to 12 mm. Using the finite element method, the contact parameters, including the maximum contact pressure and contact area, have been evaluated in light of the Hertzian contact theory. The simulation was performed statically with dissipated energy and asymmetric behavior. The types of interaction were surface-to-surface contact and normal contact behavior.

RESULTS

The maximum contact pressures in the inner liner (UHMWPE) at a head diameter of 28 mm and 36 mm are between 3.7-13.5 MPa and 2.7-10.4 MPa, respectively. The maximum von Mises of the inner liner, outer liner, and acetabular cup are 2.4-11.4 MPa, 15.7-44.3 MPa, and 3.7-12.6 MPa, respectively, for 28 mm head. Then the maximum von Mises stresses of the 36 mm head are 1.9-8.9 MPa for the inner liner, 9.9-32.8 MPa for the outer liner, and 2.6-9.9 MPa for the acetabular cup. A head with a diameter of 28 mm should have an inner liner with a thickness of 12 mm. Whereas the head diameter was 36 mm, an inner liner thickness of 8 mm was suitable.

CONCLUSION

The contact pressures and von Mises stresses generated during this research can potentially be exploited in estimating the wear of dual-mobility artificial hip joints in general. Contact pressure and von Mises stress reduce with an increasing head diameter and inner liner's thickness. Present findings would become one of the references for orthopedic surgery for choosing suitable bearing geometric parameter of hip implant.

Model-Based Acetabular Cup Orientation Optimization Based On Minimizing the Risk of Edge-Loading and Implant Impingement Following Total Hip Arthroplasty

In this paper, a computationally-efficient model-based method for determining patient-specific optimal acetabular cup alignment for total hip arthroplasty (THA) is presented. The proposed algorithm minimizes the risk of implant impingement and edge-loading, which are reported as the major causes of hip dislocation following THA. First, by using motion capture data recorded from the patient performing different daily activities, the hip contact force and the relative orientation of the femur and pelvis are calculated by a musculoskeletal model. Then, by defining two quantitative indices i.e., angular impingement distance and angular edge-loading distance, the risk of impingement and edge-loading are assessed for a wide range of cup alignments. And finally, three optimization criteria are introduced to estimate the optimal cup alignment with a tradeoff between the risk of impingement and edge-loading. The results show that patient-specific characteristics such as pelvic tilt could significantly change the optimal cup alignment, especially the value of cup anteversion. Therefore, in some cases, the well-known Lewinnek safe zone may not be optimal, or even safe. Unlike other dynamic model-based methods, in this work, the need for force plate measurements is eliminated by estimating the ground reaction forces and moments, which makes this method more practical and cost-efficient. Furthermore, the low computational complexity due to analytical formulas makes this method suitable for both preoperative and intra-operative planning.

The effect of seated pelvic tilt on posterior edge-loading in total hip arthroplasty: A finite element investigation

Edge-loading of a ceramic-on-ceramic total hip replacement can lead to reproducible squeaking and revision. A patient’s functional acetabular cup orientation, driven by their pelvic tilt, has been shown to be a significant factor in squeaking during hip flexion. The aim of this study was to investigate the effect of seated pelvic tilt on the contact mechanics at the ceramic bearing surface. A finite element model of a ceramic-on-ceramic total hip replacement was created. The cup was orientated at 40° inclination and 15° anteversion relative to the anterior pelvic plane. The stem was flexed 90° to replicate sitting in a chair. The model was loaded using data from in vivo measurements taken during a sit-to-stand activity. The pelvis was modelled in seven different sagittal positions, ranging from −30° to 30° of pelvic tilt, where a positive value denotes anterior pelvic tilt. Three different head sizes were investigated: 32, 36 and 40 mm. The maximum contact pressure and contact patch to rim distance were determined for each of the 21 simulations. Edge-loading (contact patch to rim distance < 0 mm) occurred with all head sizes when seated pelvic tilt was ≥10° and induced a large increase in contact pressure on the liner, with a maximum pressure exceeding 500 MPa. Edge-loading initiated at seated pelvic tilts of 7°, 9° and 5° for the 32, 36 and 40 mm heads, respectively. Patients with anterior pelvic tilts in the seated position are susceptible to posterior edge-loading. As the position of the pelvis when seated is patient specific, cup orientation should be adjusted on an individual basis to minimise edge-loading.

Zirconia phase transformation in retrieved, wear simulated, and artificially aged ceramic femoral heads

Zirconia in Zirconia toughened alumina ceramic hip replacements exists in an unstable state and can transform in response to stress giving the material improved fracture toughness. Phase transformation also occurs under hydrothermal conditions such as exist in vivo. To predict the hydrothermal aging that will occur in vivo accelerated aging procedures have been used, but validation of these models requires the study of retrieved hip joints. Here 26 retrievals are analysed to determine the degree of phase transformation in vivo. These were compared with virgin heads, heads that had undergone the accelerated aging process and heads wear tested to 5 million cycles in a hip simulator. Monoclinic content and surface roughness were measured using Raman spectroscopy and white light interferometry respectively. The monoclinic content for retrieved heads was 28.5% ± 7.8, greater than twice that in virgin, aged, or wear tested heads and did not have a significant correlation with time, contrary to the predictions of the hydrothermal aging model. The surface roughness for retrieved heads in the unworn area was not significantly different to that in virgin, aged, or unworn areas of wear tested heads. However in worn areas of the retrieved heads, the surface roughness was higher than observed in wear simulator testing. These results indicate that current testing methodologies do not fully capture the operational conditions of the material and the real performance of future new materials may not be adequately predicted by current pre-clinical testing methods. © 2017 The Authors. Journal of Orthopaedic Research Published by Wiley Periodicals, Inc. on behalf of Orthopaedic Research Society 35:2781-2789, 2017.

Diamond-like carbon coatings with zirconium-containing interlayers for orthopedic implants

Six types of diamond-like carbon (DLC) coatings with zirconium (Zr)-containing interlayers on titanium alloy (Ti-6Al-4V) were investigated for improving the biotribological performance of orthopedic implants. The coatings consist of three layers: above the substrate a layer stack of 32 alternating Zr and ZrN sublayers (Zr:ZrN), followed by a layer comprised of Zr and DLC (Zr:DLC), and finally a N-doped DLC layer. The Zr:ZrN layer is designed for increasing load carrying capacity and corrosion resistance; the Zr:DLC layer is for gradual transition of stress, thus enhancing layer adhesion; and the N-doped DLC layer is for decreasing friction, squeaking noises and wear. Biotribological experiments were performed in simulated body fluid employing a ball-on-disc contact with a Si₃N₄ ball and a rotational oscillating motion to mimic hip motion in terms of gait angle, dynamic contact pressures, speed and body temperature. The results showed that the Zr:DLC layer has a substantial influence on eliminating delamination of the DLC from the substrates. The DLC/Si₃N₄ pairs significantly reduced friction coefficient, squeaking noise and wear of both the Si₃N₄ balls and the discs compared to those of the Ti-6Al-4V/Si₃N₄ pair after testing for a duration that is equivalent to one year of hip motion in vivo.

An estimation of the incidence of squeaking and revision surgery for squeaking in ceramic-on-ceramic total hip replacement: a meta-analysis and report from the Australian Orthopaedic Association National Joint Registry

Squeaking arising from a ceramic-on-ceramic (CoC) total hip replacement (THR) may cause patient concern and in some cases causes patients to seek revision surgery. We performed a meta-analysis to determine the incidence of squeaking and the incidence of revision surgery for squeaking. A total of 43 studies including 16,828 CoC THR that reported squeaking, or revision for squeaking, were entered into the analysis. The incidence of squeaking was 4.2% and the incidence of revision for squeaking was 0.2%. The incidence of squeaking in patients receiving the Accolade femoral stem was 8.3%, and the incidence of revision for squeaking in these patients was 1.3%.

Hip abduction can prevent posterior edge loading of hip replacements

Edge loading causes clinical problems for hard-on-hard hip replacements, and edge loading wear scars are present on the majority of retrieved components. We asked the question: are the lines of action of hip joint muscles such that edge loading can occur in a well-designed, well-positioned acetabular cup? A musculoskeletal model, based on cadaveric lower limb geometry, was used to calculate for each muscle, in every position within the complete range of motion, whether its contraction would safely pull the femoral head into the cup or contribute to edge loading. The results show that all the muscles that insert into the distal femur, patella, or tibia could cause edge loading of a well-positioned cup when the hip is in deep flexion. Patients frequently use distally inserting muscles for movements requiring deep hip flexion, such as sit-to-stand. Importantly, the results, which are supported by in vivo data and clinical findings, also show that risk of edge loading is dramatically reduced by combining deep hip flexion with hip abduction. Patients, including those with sub-optimally positioned cups, may be able to reduce the prevalence of edge loading by rising from chairs or stooping with the hip abducted.

Concomitant evolution of wear and squeaking in dual-severity, lubricated wear testing of ceramic-on-ceramic hip prostheses

Ceramic-on-ceramic (CoC) hip bearings were tested in short-term wear tests with a systematically varied contact force. Continuous vibration and intermittent surface roughness measurements were obtained to elucidate potential causes of in vivo hip joint squeaking. The three-phase test comprised alternating cycles of edge loading (EL) and concentric articulation (CA), always using ample serum lubricant. A 50,000-cycle wear trial in which the contact force during CA was distant from the head's wear patch yielded no squeaking and practically no liner roughening. In 10-cycle trials of an edge-worn head coupled with a pristine liner, the contact force was varied in magnitude and point of application; immediate, recurrent squeaking occurred only when the contact force exceeded a critical threshold value and was centered upon the head's wear patch. In a 27,000-cycle wear trial with the contact force applied near the margin of the head's wear patch, recurrent squeaking emerged progressively as the liner's inner surface was roughened via its articulation with the worn portion of the head. The results reveal key conditions that yield recurrent squeaking in vitro in various scenarios without resorting to implausible dry conditions. A fundamental theory explains that hip squeaking is induced by myriad stress waves emanating from asperity collisions; yet, the root cause is edge loading.

Assessment of the applicability of the Hertzian contact theory to edge-loaded prosthetic hip bearings

The components of prosthetic hip bearings may experience in-vivo subluxation and edge loading on the acetabular socket as a result of joint laxity, causing abnormally high, damaging contact stresses. In this research, edge-loaded contact of prosthetic hips is examined analytically and experimentally in the most commonly used categories of material pairs. In edge-loaded ceramic-on-ceramic hips, the Hertzian contact theory yields accurate (conservatively, <10% error) predictions of the contact dimensions. Moreover, the Hertzian theory successfully captures slope and curvature trends in the dependence of contact patch geometry on the applied load. In an edge-loaded ceramic-on-metal pair, a similar degree of accuracy is observed in the contact patch length; however, the contact width is less accurately predicted due to the onset of subsurface plasticity, which is predicted for loads >400N. The Hertzian contact theory is shown to be ill-suited to edge-loaded ceramic-on-polyethylene pairs due to polyethylene's nonlinear material behavior. This work elucidates the methods and the accuracy of applying classical contact theory to edge-loaded hip bearings. The results help to define the applicability of the Hertzian theory to the design of new components and materials to better resist severe edge loading contact stresses.

Influence of acetabular cup rim design on the contact stress during edge loading in ceramic-on-ceramic hip prostheses

The purpose of the study was to investigate the contact stresses in 3 different acetabular cup rim designs (new, worn, chamfer) during edge loading, after microseparation of ceramic on ceramic hip prostheses. A 3-dimensional finite element analysis was conducted for a 28-mm diameter alumina ceramic bearing with a radial clearance of 40 μm using a normal load of 2500 N under edge loading. At a separation distance of 250 μm, the maximum tensile stress in the "new" design was of similar magnitude to the flexural strength of the alumina material that supports the localized breakdown (stripe wear) of the acetabular cup surface observed clinically. Introducing a 2.5-mm radius chamfer should reduce the maximum tensile stress in the region of 60%.

Multi-body simulation of a canine hind limb: model development, experimental validation and calculation of ground reaction forces

BACKGROUND

Among other causes the long-term result of hip prostheses in dogs is determined by aseptic loosening. A prevention of prosthesis complications can be achieved by an optimization of the tribological system which finally results in improved implant duration. In this context a computerized model for the calculation of hip joint loadings during different motions would be of benefit. In a first step in the development of such an inverse dynamic multi-body simulation (MBS-) model we here present the setup of a canine hind limb model applicable for the calculation of ground reaction forces.

METHODS

The anatomical geometries of the MBS-model have been established using computer tomography- (CT-) and magnetic resonance imaging- (MRI-) data. The CT-data were collected from the pelvis, femora, tibiae and pads of a mixed-breed adult dog. Geometric information about 22 muscles of the pelvic extremity of 4 mixed-breed adult dogs was determined using MRI. Kinematic and kinetic data obtained by motion analysis of a clinically healthy dog during a gait cycle (1 m/s) on an instrumented treadmill were used to drive the model in the multi-body simulation.

RESULTS AND DISCUSSION

As a result the vertical ground reaction forces (z-direction) calculated by the MBS-system show a maximum deviation of 1.75%BW for the left and 4.65%BW for the right hind limb from the treadmill measurements. The calculated peak ground reaction forces in z- and y-direction were found to be comparable to the treadmill measurements, whereas the curve characteristics of the forces in y-direction were not in complete alignment.

CONCLUSION

In conclusion, it could be demonstrated that the developed MBS-model is suitable for simulating ground reaction forces of dogs during walking. In forthcoming investigations the model will be developed further for the calculation of forces and moments acting on the hip joint during different movements, which can be of help in context with the in silico development and testing of hip prostheses.

Fatigue failure in the cement mantle of a simplified acetabular replacement model

Although the role of fatigue failure in aseptic loosening of cemented total hip replacements has been extensively studied in femoral components, studies of fatigue failure in cement mantle of acetabular replacements have yet to be reported, despite that the long-term failure rate in the latter is about three times that of femoral components. Part of the reason may be that a complex pelvic bone structure does not land itself readily for a 2D representation as that of a femur.In this work, a simple multilayer model has been developed to reproduce the stress distributions in the cement mantle of an acetabular replacement from a plane strain finite element pelvic bone model. The experimental multilayer model was subjected to cyclic loading up to peak hip contact force during normal walking. Radial fatigue cracks were observed in the vicinity of the maximum tangential and compressive stresses, as predicted by the FE models. Typical fatigue striations were also observed on the fracture surfaces post cyclic testing. The results were examined in the context of retrieval studies, 3D FE analysis and in vitro experimental results using full-sized hemi-pelvic bone models.

[FE-analysis of surface stresses for the tribological system in total hip prostheses]

The implantation of a total hip prosthesis is an operation which is performed frequently due to advanced hip joint damage both in humans and in veterinary medicine in dogs. The long-term result of a hip prosthesis is mainly determined by aseptic loosening of the prosthesis; among other causes, abrasion particles of the tribological pairing are responsible for the loosening. For the analysis of the surface stresses with different tribological pairings, a finite element model was generated which was based on the CAD data of a commercial total hip prosthesis. After transmission of a physiological force in the components of the three tribological pairings ceramic/polyethylene, ceramic/ceramic and metal/polyethylene, stresses were calculated. Stresses in the ceramic/ceramic tribological pairings were conspicuously higher than in the other material pairings. In the future adapted prostheses have to be developed that ensure optimal friction and absorption characteristics of the components.

Failure of an uncemented acetabular prosthesis - a case study

Severe wear and aseptic loosening in an uncemented acetabular prosthesis have been observed in a revision surgery carried out at King Edwards VII hospital by L. Taylor and P. Heaton-Adegbile, twelve years following the primary total hip replacement operation. The superior-lateral wall of the polyethylene liner and part of the titanium cup were found to be completely worn out, such that the ceramic head was in direct articulation with the titanium cup.A three-dimensional finite element model was developed. The polyethylene liner was modelled with the outer surface of the liner fully constrained to represent the much stiffer metal cup. Contact analyses were performed between the articulating surfaces under physiological loading conditions, including normal walking, climbing upstairs and downstairs, using the finite element software ANSYS. The results show high initial contact pressure along the periphery of the liner due to the oversize of the femoral head. The maximum contact pressure was found in the superior-posterior quadrant, which correlates well with the location and the direction of the wear. Both wear particles and stress shielding may have contributed to the periprosthetic bone loss and ultimately the late loosening. Reduction of the interference between the liner and the femoral head seems to be effective in the reduction of the initial contact pressure.

Effect of microseparation on contact mechanics in ceramic-on-ceramic hip joint replacements

The contact mechanics in ceramic-on-ceramic hip implants are investigated in this study under the microseparation condition where the edge contact occurs between the superolateral rim of the acetabular cup and the femoral head. A three-dimensional finite element model is developed to examine the effect of the microseparation distance between the femoral head and the acetabular cup on the contact area and contact stresses between the bearing surfaces. It is shown that microseparation leads to edge contact and elevated contact stresses, and these are mainly dependent on the magnitude of separation, the radial clearance between the femoral head and the acetabular cup, and the cup inclination angle. For a small microseparation distance (less than the diametrical clearance), the contact occurs within the acetabular cup, and consequently an excellent agreement of the predicted contact pressure distribution is obtained between the present three-dimensional anatomical model and a simple two-dimensional axisymmetric model adopted in a previous study [5]. However, as microsegregation is increased further, edge contact between the superolateral rim and the femoral head occurs. Consequently, the predicted contact pressure is significantly increased. The corresponding contact area resembles closely the stripe wear pattern observed on both clinically retrieved and simulator-tested ceramic femoral heads [8, 9, 11]. Furthermore, introducing a fillet radius of 2.5 mm at the mouth of the acetabular cup is shown to reduce the contact stress due to edge contact, but only under relatively large microseparation distances.