A New Formulation for the Prediction of Polyethylene Wear in Artificial Hip Joints

The influence of cross shear and contact pressure on the wear of UHMWPE-on-PEEK-OPTIMA™ for use in total knee replacement

PEEK-OPTIMA™ polymer is being considered as an alternative material to cobalt chrome in the femoral component of total knee arthroplasty to give a metal-free knee replacement system. Simple geometry pin-on-plate wear simulation can be used to systematically investigate and understand the wear of materials under many different conditions. The aim of this study was to investigate the wear of UHMWPE-on-PEEK-OPTIMA™ under a range of contact pressure (2.1-80 MPa) and cross-shear ratio (0-0.18) conditions. With increasing contact pressure, there was a trend of decreasing UHMWPE wear factor with a significant difference (p<0.001) in the wear factor of UHMWPE under the different contact pressure conditions of interest. Under uniaxial motion (cross-shear ratio = 0), the wear of UHMWPE was low, introducing multi-axial motion increased the wear of the UHMWPE. There was a significant difference (p<0.01) in the wear factor at different cross-shear ratios however, post hoc analysis showed only the study carried out under unidirectional motion to be significantly different from the other conditions. With varying contact pressure and cross-shear ratio, the wear of UHMWPE against PEEK-OPTIMA™ polymer showed similar trends to previous studies of UHMWPE-on-cobalt chrome.

Polyethylene wear simulation models applied to a prosthetic hip joint based on unidirectional articulations

Ultra-high molecular weight polyethylene (UHMWPE) is commonly used as soft-bearing material in total joint replacements. However, the release of polymeric wear debris is still related to complications leading to aseptic loosening. Recently, a novel hip prosthesis showing reduced wear was developed by the authors of this study, consisting of unidirectional cylindrical articulations instead of the conventional multidirectional ball-and-socket design. This study evaluates four different theoretical wear models applied to this new design. The calculated volumetric wear was compared to experimental results. Although all models provided a good indication of the wear rates for the ball-and-socket prosthesis, they exhibited high discrepancies when predicting the amount of wear of the new unidirectional design. It was observed that the closest agreement with experimental results was obtained by the models that consider the friction-induced molecular orientation phenomenon exhibited by UHMWPE.

Computational wear of knee implant polyethylene insert surface under continuous dynamic loading and posterior tibial slope variation based on cadaver experiments with comparative verification

Background

The effect of posterior tibial slope on the maximum contact pressure and wear volume of polyethylene (PE) insert were not given special attention. The effects of flexion angle, Anterior-Posterior (AP) Translation, and Tibial slope on the max contact pressure and wear of PE insert of TKR were investigated under loadings which were obtained in cadaver experiments by using Archard’s wear law. This study uses not only loads obtained from cadaver experiments but also dynamic flexion starting from 0 to 90 degrees.

Method

Wear on knee implant PE insert was investigated using a 2.5 size 3 dimensional (3D) cruciate sacrificing total knee replacement model and Finite Element Method (FEM) under loadings and AP Translation data ranging from 0 to 90 flexion angles validated by cadaver experiments. Two types of analyses were done to measure the wear effect on knee implant PE insert. The first set of analyses included the flexion angles dynamically changing with the knee rotating from 0 to 90 angles according to the femur axis and the transient analyses for loadings changing with a certain angle and duration.

Results

It is seen that the contact pressure on the PE insert decreases as the cycle increases for both Flexion and Flexion+AP Translation. It is clear that as the cycle increases, the wear obtained for both cases increases. The loadings acting on the PE insert cannot create sufficient pressure due to the AP Translation effect at low speeds and have an effect to reduce the wear, while the effect increases with the wear as the cycle increases, and the AP Translation now contributes to the wear at high speeds. It is seen that as the posterior tibial slope angle increases, the maximum contact pressure values slightly decrease for the same cycle.

Conclusions

This study indicated that AP Translation, which changes direction during flexion, had a significant effect on both contact pressure and wear. Unlike previous similar studies, it was seen that the amount of wear continues to increase as the cycle increases. This situation strengthens the argument that loading and AP Translation values that change with flexion shape the wear effects on PE Insert.

Development and Validation of a Finite Element Model of Wear in UHMWPE Liner Using Experimental Data From Hip Simulator Studies

The wear of acetabular liner is one of the key factors determining osseointegration and long-term performance of total hip joint replacement implants. The experimental measurements of wear in total hip replacement components are time and cost-intensive. While addressing this aspect, a finite element model of a hip joint bearing consisting of zirconia-toughened alumina femoral head and ultrahigh molecular weight polyethylene liner was developed to predict the dynamic wear response of the liner. The Archard-Lancaster equation, consisting of surface contact pressure, wear rate, and sliding distance, was employed to predict the wear of the acetabular liner. The contact pressure and wear at the articulating surface were found to decrease over time. A new computational method involving three-dimensional point clouds from the finite element analyzed results were used to construct wear maps. The model was able to predict the linear wear, over 2 × 106 cycles with relative errors ranging from 9% to 36% when compared to the published results. The increasing error percentage occurring primarily from the use of a constant wear rate was reduced to a maximum of 17% by introducing a correction factor. The volumetric rate was predicted with a maximum relative error of 7% with the implementation of the correction factor. When the model was implemented to study acetabular liners of diameters ranging from 28 to 36 mm, the linear wear was seen to decrease with an increase in femoral head diameter, which is in agreement with the clinical data. This study emphasizes the need to develop more such FEA-based computational studies to reliably predict and correlate with experimentally measured temporal evolution of wear of load-bearing articulating joints.

A novel hip joint prosthesis with uni-directional articulations for reduced wear

A novel polymer-on-metal hip joint prosthesis design that makes use of uni-directional articulations was developed and tested in this work. The new implant was tested using two polymer variants, virgin ultra-high molecular weight polyethylene (UHMWPE), and Vitamin E-infused highly crosslinked polyethylene (VEHXPE). The degrees of freedom of the ball-and-socket are reproduced by three cylindrical orthogonally-aligned articulations. This unconventional design leverages on the molecular orientation hardening mechanisms of the polyethylene and increased contact area to minimize wear. An experimental hip joint simulator was used to compare the gravimetric wear of the conventional ball-on-socket and the new implant. The new prosthesis including UHMWPE components produced a 78% reduction in wear, whereas the new prosthesis with VEHXPE components produced a 100% reduction in wear, as no measurable wear was detected. Machining marks on the acetabular cups of the new prosthesis were retained for both polyethylene variants, further demonstrating the low levels of wear exhibited by the new implants. Both polyethylene materials produced particles in the range of 0.1-1.0 μm, which are the most biologically active. Nonetheless, the extremely low wear rates are likely to induce minimal osteolysis effects. Furthermore, the novel design also offers an increase of more than 24% in the range of motion in flexion/extension when compared to a dual-mobility hip implant. A prototype of the prosthesis was implanted into a Thiel-embalmed human cadaver during a mock-surgery, which demonstrated high resistance to dislocation and the possibility of performing a figure of four position.

Wear performance of inverted non-conforming bearings in anatomic total shoulder arthroplasty

BACKGROUND

Glenoid component failures still represent the most common complication in total shoulder arthroplasty. These failures depend on several factors, including ultra-high molecular weight polyethylene (UHMWPE) wear. One reason for UHMWPE wear in total shoulder arthroplasty may be the current use of a spherical prosthetic humeral head against a radially mismatched UHMWPE glenoid component, which leads to reduced glenohumeral translations, glenoid edge loading and high translational forces during shoulder motions. The aim of this study was to assess the in vitro wear of an anatomic total shoulder prosthesis with non-spherical non-conforming bearings with inverted conventional materials.

METHODS

The wear of a vitamin E-blended UHMWPE non-spherical humeral head articulating against a non-conforming titanium-niobium nitride (TiNbN)-coated metallic glenoid was tested using a joint simulator. The wear test was performed by applying a constant load of 756 N with angular motions and translations.

RESULTS

After 2.5 million cycles, the mean wear rate of the humeral head was 0.28 ± standard deviation (SD) 0.45 mg/million cycles.

CONCLUSION

The low wear rate of the vitamin E UHMWPE humeral head supports the use of non-spherical non-conforming bearings with inverted conventional materials in anatomic total shoulder arthroplasty.

Enhanced In-Silico Polyethylene Wear Simulation of Total Knee Replacements During Daily Activities

A computational wear simulator is an efficient tool for evaluating the wear of artificial knee joints. The classical Archard's wear law-based simulator has questionable accuracy and is focused on walking. In this study, an in silico polyethylene wear simulation of total knee replacements was developed considering the various highly demanding daily activities. A good predicted accuracy (error = 8.1%) was found through comparison of the experimental results. A relatively larger averaged wear loss was found under the loading condition (1.53 mg/mc) of daily activities compared with the walking condition (1.32 mg/mc). The squatting movement (2.57 mg/mc) produces the highest overall wear rate. In addition, a relatively larger amount of wear was found on the medial side knee prosthesis than that on the lateral side. The enhanced in silico polyethylene wear simulator provides an accurate and comprehensive tool for wear prediction in preclinical wear testing.

An efficient and robust simulator for wear of total knee replacements

Wear on total knee replacements is an important criterion for their performance characteristics. Numerical simulations of such wear have seen increasing attention over the last years. They have the potential to be much faster and less expensive than the in vitro tests in use today. While it is unlikely that in silico tests will replace actual physical tests in the foreseeable future, a judicious combination of both approaches can help making both implant design and pre-clinical testing quicker and more cost-effective. The challenge today for the design of simulation methods is to obtain results that convey quantitative information and to do so quickly and reliably. This involves the choice of mathematical models as well as the numerical tools used to solve them. The correctness of the choice can only be validated by comparing with experimental results. In this article, we present finite element simulations of the wear in total knee replacements during the gait cycle standardized in the ISO 14243-1 document, used for compliance testing in several countries. As the ISO 14243-1 standard is precisely defined and publicly available, it can serve as an excellent benchmark for comparison of wear simulation methods. We use comparatively simple wear and material models, but we solve them using a new wear algorithm that combines extrapolation of the geometry changes with a contact algorithm based on nonsmooth multigrid ideas. The contact algorithm works without Lagrange multipliers and penalty parameters, achieving unparalleled stability and efficiency. We compare our simulation results with the experimental data from physical tests using two different actual total knee replacements. Even though the model is simple, we can predict the total mass loss due to wear after 5-million gait cycles, and we observe a good match between the wear patterns seen in experiments and our simulation results. When compared with a state-of-the-art penalty-based solver for the same model, we measure a roughly fivefold increase of execution speed.

Analytical and computational sliding wear prediction in a novel knee implant: a case study

Osteoarthritis (OA) is a commonly occurring cartilage degenerative disease. The end stage treatment is Total Knee Arthroplasty (TKA), which can be costly in terms of initial surgery, but also in terms of revision knee arthroplasty, which is quite often required. A novel conceptual knee implant has been proposed to function as a reducer of stress across the joint surface, to extend the period of time before TKA becomes necessary. The objective of this paper is to develop a computational model which can be used to assess the wear arising at the implant articulating surfaces. Experimental wear coefficients were determined from physical testing, the results of which were verified using a semi-analytical model. Experimental results were incorporated into an anatomically correct computational model of the knee and implant. The wear-rate predicted for the implant was 27.74 mm³ per million cycles (MC) and the wear depth predicted was 1.085 mm/MC. Whereas the wear-rate is comparable to that seen in conventional knee implants, the wear depth is significantly higher than for conventional knee prostheses, and indicates that, in order to be viable, wear-rates should be reduced in some way, perhaps by using low-wear polymers.

Finite element analysis of polyethylene wear in total hip replacement: A literature review

Evaluation and prediction of wear play a key role in product design and material selection of total hip replacements, because wear debris is one of the main causes of loosening and failure. Multifactorial clinical or laboratory studies are high cost and require unfeasible timeframes for implant development. Simulation using finite element methods is an efficient and inexpensive alternative to predict wear and pre-screen various parameters. This article presents a comprehensive literature review of the state-of-the-art finite element modelling techniques that have been applied to evaluate wear in polyethylene hip replacement components. A number of knowledge gaps are identified including the need to develop appropriate wear coefficients and the analysis of daily living activities.

In vivo sliding distance on the metal-on-polyethylene total hip arthroplasty articulation using patient-specific gait analysis

Metal-on-polyethylene (MoP) is the most commonly used bearing surface in primary total hip arthroplasty (THA). Polyethylene wear debris remains a major concern. Studies investigating the wear performance based on patient-specific in vivo kinematics and component orientation remains largely lacking. The primary goal of this study was to identify patterns of the distribution of sliding distance and cross-shear ratio among THA patients. A validated approach combining dual fluoroscopic imaging system and computed-tomography was utilized to quantify in vivo gait kinematics and component orientations in 48 total hips. The distribution of accumulated sliding distance and cross-shear ratio over the polyethylene bearing surface was calculated and analyzed using principal component analysis (PCA). Strong patient-specific variation in sliding distance and cross-shear ratio was observed. PCA detected two principal components (PCs) of the sliding distance that together contribute to 94.8% of the total variation. PCA detected four PCs that together contribute to 86% of the total variation of the cross-shear ratio. Regression analysis identified a positive association between cross-shear magnitude and axial and frontal range of motion (RoM). Increased cup inclination, stem anteversion, and reduced cup anteversion may lead to superiorly distributed high cross-shear region, potentially accelerating wear. Our study investigated, in vivo sliding distance and cross-shear pattern using a comprehensive patient-specific dataset and detected several wear indicators under in vivo conditions. These findings provided useful reference values that may help to assess wear in MoP THA patients. © 2018 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 36:3151-3160, 2018.

A closed-form formulation for the conformal articulation of metal-on-polyethylene hip prostheses: Contact mechanics and sliding distance

Using Hertz contact law results in inaccurate outcomes when applied to the soft conformal hip implants. The finite element method also involves huge computational time and power. In addition, the sliding distance computed using the Euler rotation method does not incorporate tribology of bearing surfaces, contact mechanics and inertia forces. This study, therefore, aimed to develop a nonlinear dynamic model based on the multibody dynamic methodology to predict contact pressure and sliding distance of metal-on-polyethylene hip prosthesis, simultaneously, under normal walking condition. A closed-form formulation of the contact stresses distributed over the articulating surfaces was derived based upon the elastic foundation model, which reduced computational time and cost significantly. Three-dimensional physiological loading and motions, inertia forces due to hip motion and energy loss during contact were incorporated to obtain contact properties and sliding distance. Comparing the outcomes with that available in the literature and a finite element analysis allowed for the validation of our approach. Contours of contact stresses and accumulated sliding distances at different instants of the walking gait cycle were investigated and discussed. It was shown that the contact point at each instant was located within the zone with the corresponding highest accumulated sliding distance. In addition, the maximum contact pressure and area took place at the stance phase with a single support. The stress distribution onto the cup surface also conformed to the contact point trajectory and the physiological loading.

The influence of simulator input conditions on the wear of total knee replacements: An experimental and computational study

Advancements in knee replacement design, material and sterilisation processes have provided improved clinical results. However, surface wear of the polyethylene leading to osteolysis is still considered the longer-term risk factor. Experimental wear simulation is an established method for evaluating the wear performance of total joint replacements. The aim of this study was to investigate the influence of simulation input conditions, specifically input kinematic magnitudes, waveforms and directions of motion and position of the femoral centre of rotation, on the wear performance of a fixed-bearing total knee replacement through a combined experimental and computational approach. Studies were completed using conventional and moderately cross-linked polyethylene to determine whether the influence of these simulation input conditions varied with material. The position of the femoral centre of rotation and the input kinematics were shown to have a significant influence on the wear rates. Similar trends were shown for both the conventional and moderately cross-linked polyethylene materials, although lower wear rates were found for the moderately cross-linked polyethylene due to the higher level of cross-linking. The most important factor influencing the wear was the position of the relative contact point at the femoral component and tibial insert interface. This was dependent on the combination of input displacement magnitudes, waveforms, direction of motion and femoral centre of rotation. This study provides further evidence that in order to study variables such as design and material in total knee replacement, it is important to carefully control knee simulation conditions. This can be more effectively achieved through the use of displacement control simulation.

A comprehensive combined experimental and computational framework for pre-clinical wear simulation of total knee replacements

A more robust pre-clinical wear simulation framework is required in order to simulate wider and higher ranges of activities, observed in different patient populations such as younger more active patients. Such a framework will help to understand and address the reported higher failure rates for younger and more active patients (National_Joint_Registry, 2016). The current study has developed and validated a comprehensive combined experimental and computational framework for pre-clinical wear simulation of total knee replacements (TKR).

The input mechanical (elastic modulus and Poisson’s ratio) and wear parameters of the moderately cross-linked ultra-high molecular weight polyethylene (UHMWPE) bearing material were independently measured from experimental studies under realistic test conditions, similar to the loading conditions found in the total knee replacements. The wear predictions from the computational wear simulation were validated against the direct experimental wear measurements for size 3 Sigma curved total knee replacements (DePuy, UK) in an independent experimental wear simulation study under three different daily activities; walking, deep squat, and stairs ascending kinematic conditions.

The measured compressive mechanical properties of the moderately cross-linked UHMWPE material were more than 20% lower than that reported in the literature under tensile test conditions. The pin-on-plate wear coefficient of moderately cross-linked UHMWPE was significantly dependant of the contact stress and the degree of cross-shear at the articulating surfaces.

The computational wear predictions for the TKR from the current framework were consistent and in a good agreement with the independent full TKR experimental wear simulation measurements, with 0.94 coefficient of determination of the framework. In addition, the comprehensive combined experimental and computational framework was able to explain the complex experimental wear trends from the three different daily activities investigated. Therefore, such a framework can be adopted as a pre-clinical simulation approach to optimise different designs, materials, as well as patient’s specific total knee replacements for a range of activities.

THE EFFECT OF ASPHERICITY OF ACETABULAR BEARING SURFACE ON CONTACT MECHANICS OF UHMWPE TOTAL HIP IMPLANTS BY FINITE ELEMENT ANALYSIS

Asphericity and out-of-roundness are generally used to evaluate the manufacturing quality of ultra-high molecular weight polyethylene (UHMWPE) cup inner surfaces, which can potentially affect initial clinical wear and contribute to osteolysis of total hip arthroplasty. This study measured the location and magnitude of asphericity and the out-of-roundness value for four UHMWPE cups in a single set, and then investigated the effects of the asphericity on the contact mechanics of UHMWPE cups. A co-ordinate measuring machine (CMM) was used for the surface measurement and finite element analysis (FEA) was adopted for contact mechanics study. The results demonstrated that the asphericity varied between cups with the maximum value as 0.088[Formula: see text][Formula: see text][Formula: see text]0.004[Formula: see text]mm. Although such a value met the ISO specification, large difference of volume appeared for the asphericity above 0.060[Formula: see text]mm. Actual surface profile accounting for the asphericity was found to affect the value of contact pressure and contact area by around 12%. The inferior asphericity resulted in a nonsmoothly distributed contact pressure, which had a negative effect on the contact mechanics of UHMWPE cups and the edge loading was predicted to occur for the sample with a large asphericity. In conclusion, the asphericity of UHMWPE cup could affect the contact mechanics of the articular bearings and may subsequently contribute to initial wear during bedding-in phase.

Patient-specific hip geometry has greater effect on THA wear than femoral head size

In vivo linear penetration in total hip arthroplasty (THA) exhibits similar values for 28mm and 32mm femoral head diameter with considerable variations between and within the studies. It indicates factors other than femoral head diameter influence polyethylene wear. This study is intended to test the effect of patient׳s individual geometry of musculoskeletal system, acetabular cup orientation, and radius of femoral head on wear. Variation in patient׳s musculoskeletal geometry and acetabular cup placement is evaluated in two groups of patients implanted with 28mm and 32mm THA heads. Linear wear rate estimated by mathematical model is 0.165-0.185mm/year and 0.157-0.205mm/year for 28 and 32mm THA heads, respectively. Simulations show little influence femoral head size has on the estimated annual wear rate. Predicted annual linear wear depends mostly on the abduction angle of the acetabular cup and individual geometry of the musculoskeletal system of the hip, with the latter having the greatest affect on variation in linear wear rate.

Effect of size and dimensional tolerance of reverse total shoulder arthroplasty on wear: An in-silico study

Although huge research efforts have been devoted to wear analysis of ultra-high molecular weight polyethylene (UHMWPE) in hip and knee implants, shoulder prostheses have been studied only marginally. Recently, the authors presented a numerical wear model of reverse total shoulder arthroplasties (RTSAs), and its application for estimating the wear coefficient k from experimental data according to different wear laws. In this study, such model and k expressions are exploited to investigate the sensitivity of UHMWPE wear to implant size and dimensional tolerance. A set of 10 different geometries was analysed, considering nominal diameters in the range 36-42mm, available on the market, and a cup dimensional tolerance of +0.2, -0.0mm (resulting in a diametrical clearance ranging between 0.04-0.24mm), estimated from measurements on RTSAs. Since the most reliable wear law and wear coefficient k for UHMWPE are still controversial in the literature, both the Archard law (AR) and the wear law of UHMWPE (PE), as well as four different k expressions were considered, carrying out a total of 40 simulations. Results showed that the wear volume increases with the implant size and decreases with the dimensional tolerance for both the wear laws. Interestingly, different trends were obtained for the maximum wear depth vs. clearance: the best performing implants should have a high conformity according to the AR law but low conformity for the PE law. However, according to both laws, wear is highly affected by both implant size and dimensional tolerance, although it is much more sensitive to the latter, with up to a twofold variation of wear predicted. Indeed, dimensional tolerance directly alters the clearance, and therefore the lubrication and contact pressure distribution in the implant. Rather surprisingly the role of dimensional tolerance has been completely disregarded in the literature, as well as in the standards. Furthermore, this study notes some important issues for future work, such as the validation of wear laws and predictive wear models and the sensitivity of k to implant geometry.

Effect of friction and clearance on kinematics and contact mechanics of dual mobility hip implant

The dual mobility hip implant has been introduced recently and increasingly used in total hip replacement to maintain the stability and reduce the risk of post-surgery dislocation. However, the kinematics and contact mechanisms of dual mobility hip implants have not been investigated in detail in the literature. Therefore, finite element method was adopted in this study to investigate dynamics and contact mechanics of a typical metal-on-polymer dual mobility hip implant under different friction coefficient ratios between the inner and the outer articulations and clearances/interferences between the ultra-high-molecular-weight polyethylene liner and the metal back shell. A critical ratio of friction coefficients between the two pairs of contact interfaces was found to mainly determine the rotating surfaces. Furthermore, an initial clearance between the liner and the back shell facilitated the rotation of the liner while an initial interference prevented such a motion at the outer articulating interface. In addition, the contact area and the sliding distance at the outer articulating surface were markedly greater than those at the inner cup-head interface, potentially leading to extensive wear at the outer surface of the liner.

Numerical and experimental investigations for the evaluation of the wear coefficient of reverse total shoulder prostheses

In the present study, numerical and experimental wear investigations on reverse total shoulder arthroplasties (RTSAs) were combined in order to estimate specific wear coefficients, currently not available in the literature. A wear model previously developed by the authors for metal-on-plastic hip implants was adapted to RTSAs and applied in a double direction: firstly, to evaluate specific wear coefficients for RTSAs from experimental results and secondly, to predict wear distribution. In both cases, the Archard wear law (AR) and the wear law of UHMWPE (PE) were considered, assuming four different k functions. The results indicated that both the wear laws predict higher wear coefficients for RTSA with respect to hip implants, particularly the AR law, with k values higher than twofold the hip ones. Such differences can significantly affect predictive wear model results for RTSA, when non-specific wear coefficients are used. Moreover, the wear maps simulated with the two laws are markedly different, although providing the same wear volume. A higher wear depth (+51%) is obtained with the AR law, located at the dome of the cup, while with the PE law the most worn region is close to the edge. Taking advantage of the linear trend of experimental volume losses, the wear coefficients obtained with the AR law should be valid despite having neglected the geometry update in the model.

FINITE ELEMENT ANALYSIS OF A RETRIEVED CUSTOM-MADE KNEE PROSTHESIS

Custom-made knee prostheses have been widely used to reconstruct the function of the lower limb in bone tumor resections. A custom-made tumor knee prosthesis was retrieved on account of prosthesis loosening post-surgery. Misalignment between the anatomical axis of the femur and the axis of the femoral stem as well as the material loss at the posterior region of the tibial plateau were considered to be the primary causes of the failure. Based on this hypothesis, finite element analysis was performed to investigate the contact mechanics of the prosthesis while implanted in vivo. The maximum deformation at the femur was 0.59 and 1.17 mm when the misalignment angle was 3° and 6°, respectively. Besides, the maximum contact pressure at the tibial plateau was 44.88 MPa at an extremely high flexion of angle 135° during squatting or kneeling. Uneven stress distribution at the femur, which came from the misalignment, was the main cause of loosening, which was aggravated indirectly with the material loss at the posterior region of the tibial plateau. Optimized prosthesis design and appropriate selection, with accurate surgical positioning and targeted rehabilitation training programme are important considerations for prolonging life-span of prostheses in vivo.

Finite element analysis of sliding distance and contact mechanics of hip implant under dynamic walking conditions

An explicit finite element method was developed to predict the dynamic behavior of the contact mechanics for a hip implant under normal walking conditions. Two key parameters of mesh sensitivity and time steps were examined to balance the accuracy and computational cost. Both the maximum contact pressure and accumulated sliding distance showed good agreement with those in the previous studies using the implicit finite element analysis and analytical methods. Therefore, the explicit finite element method could be used to predict the contact pressure and accumulated sliding distance for an artificial hip joint simultaneously in dynamic manner.

Prediction of contact mechanics in metal-on-metal Total Hip Replacement for parametrically comprehensive designs and loads

Manufacturers and investigators of Total Hip Replacement (THR) bearings require tools to predict the contact mechanics resulting from diverse design and loading parameters. This study provides contact mechanics solutions for metal-on-metal (MoM) bearings that encompass the current design space and could aid pre-clinical design optimization and evaluation. Stochastic finite element (FE) simulation was used to calculate the head-on-cup contact mechanics for five thousand combinations of design and loading parameters. FE results were used to train a Random Forest (RF) surrogate model to rapidly predict the contact patch dimensions, contact area, pressures and plastic deformations for arbitrary designs and loading. In addition to widely observed polar and edge contact, FE results included ring-polar, asymmetric-polar, and transitional categories which have previously received limited attention. Combinations of design and load parameters associated with each contact category were identified. Polar contact pressures were predicted in the range of 0-200 MPa with no permanent deformation. Edge loading (with subluxation) was associated with pressures greater than 500 MPa and induced permanent deformation in 83% of cases. Transitional-edge contact (with little subluxation) was associated with intermediate pressures and permanent deformation in most cases, indicating that, even with ideal anatomical alignment, bearings may face extreme wear challenges. Surrogate models were able to accurately predict contact mechanics 18,000 times faster than FE analyses. The developed surrogate models enable rapid prediction of MoM bearing contact mechanics across the most comprehensive range of loading and designs to date, and may be useful to those performing bearing design optimization or evaluation.

The effect of insert conformity and material on total knee replacement wear

The mean average life is increasing; therefore, there is a need to increase the lifetime of the prostheses. To fulfil this requirement, new prosthetic designs and materials are being introduced. Two of the design parameters that may affect wear of total knee replacements, and hence the expected lifetime, are the insert conformity and material. Computational models have been used extensively for wear prediction and optimisation of artificial knee designs. The objective of the present study was to use a previously validated non-dimensional wear coefficient-based computational wear model to investigate the effect of insert conformity and material on the predicted wear in total knee replacements. Four different inserts (curved, lipped, partial flat and custom flat), with different conformity levels, were tested against the same femoral and under two different kinematic inputs (intermediate and high), with different levels of cross-shear. The insert bearing materials were either conventional or moderately cross-linked ultra-high molecular weight polyethylene (UHMWPE). Wear predictions were validated against the experimental data from Leeds knee simulation tests. The predicted wear rates for the curved insert (most conformed) were more than three times those for the flat insert (least conformed). In addition, the computationally predicted average volumetric wear rates for moderately cross-linked UHMWPE bearings were less than half of their corresponding conventional UHMWPE bearings. Moreover, the wear of the moderately cross-linked UHMWPE was shown to be less dependent on the degree of cross-shear, compared to conventional UHMWPE. These results along with supporting experimental studies provide insight into the design variables, which may reduce wear in knee replacements.

Effect of motion inputs on the wear prediction of artificial hip joints

Hip joint simulators have been largely used to assess the wear performance of joint implants. Due to the complexity of joint movement, the motion mechanism adopted in simulators varies. The motion condition is particularly important for ultra-high molecular weight polyethylene (UHMWPE) since polyethylene wear can be substantially increased by the bearing cross-shear motion. Computational wear modelling has been improved recently for the conventional UHMWPE used in total hip joint replacements. A new polyethylene wear law is an explicit function of the contact area of the bearing and the sliding distance, and the effect of multidirectional motion on wear has been quantified by a factor, cross-shear ratio. In this study, the full simulated walking cycle condition based on a walking measurement and two simplified motions, including the ISO standard motion and a simplified ProSim hip simulator motion, were considered as the inputs for wear modelling based on the improved wear model. Both the full simulation and simplified motions generated the comparable multidirectional motion required to reproduce the physiological wear of the bearing in vivo. The predicted volumetric wear of the ProSim simulator motion and the ISO motion conditions for the walking cycle were 13% and 4% lower, respectively, than that of the measured walking condition. The maximum linear wear depths were almost the same, and the areas of the wear depth distribution were 13% and 7% lower for the ProSim simulator and the ISO condition, respectively, compared with that of the measured walking cycle motion condition.

Quantification of the effect of cross-shear and applied nominal contact pressure on the wear of moderately cross-linked polyethylene

Polyethylene wear is a great concern in total joint replacement. It is now considered a major limiting factor to the long life of such prostheses. Cross-linking has been introduced to reduce the wear of ultra-high-molecular-weight polyethylene (UHMWPE). Computational models have been used extensively for wear prediction and optimization of artificial knee designs. However, in order to be independent and have general applicability and predictability, computational wear models should be based on inputs from independent experimentally determined wear parameters (wear factors or wear coefficients). The objective of this study was to investigate moderately cross-linked UHMWPE, using a multidirectional pin-on-plate wear test machine, under a wide range of applied nominal contact pressure (from 1 to 11 MPa) and under five different kinematic inputs, varying from a purely linear track to a maximum rotation of +/- 55 degrees. A computational model, based on a direct simulation of the multidirectional pin-on-plate wear tester, was developed to quantify the degree of cross-shear (CS) of the polyethylene pins articulating against the metallic plates. The moderately cross-linked UHMWPE showed wear factors less than half of that reported in the literature for, the conventional UHMWPE, under the same loading and kinematic inputs. In addition, under high applied nominal contact stress, the moderately crosslinked UHMWPE wear showed lower dependence on the degree of CS compared to that under low applied nominal contact stress. The calculated wear coefficients were found to be independent of the applied nominal contact stress, in contrast to the wear factors that were shown to be highly pressure dependent. This study provided independent wear data for inputs into computational models for moderately cross-linked polyethylene and supported the application of wear coefficient-based computational wear models.