In theory, Finite Element Analysis (FEA) is an attractive method for elucidating the mechanics of modular implant junctions, including variations in materials, designs, and modes of loading. However, the credence of any computational model can only be established through validation using experimental data. In this study we examine the validity of such a simulation validated by comparing values of interface motion predicted using FEA with values measured during experimental simulation of stair-climbing. Two finite element models (FEM) of a modular implant assembly were created for use in this study, consisting of a 36mm CoCr femoral head attached to a TiAlV rod with a 14/12 trunnion. Two head materials were modelled: CoCr alloy (118,706 10-noded tetrahedral elements), and alumina ceramic (124,710 10-noded tetrahedral elements). The quasi-static coefficients of friction (µs) of the CoCr-TiAlV and Ceramic-TiAlV interfaces were calculated from uniaxial assembly (2000N) and dis-assembly experiments performed in a mechanical testing machine (Bionix, MTS). Interface displacements during taper assembly and disassembly were measured using digital image correlation (DIC; Dantec Dynamics). The assembly process was also simulated using the computational model with the friction coefficient set to µs and solved using the Siemens Nastran NX 11.0 Solver. The frictional conditions were then varied iteratively to find the value of µ providing the closest estimate to the experimental value of head displacement during assembly. To validate the FEA model, the relative motion between the head and the trunnion was measured during dynamic loading simulating stair-climbing. Each modular junction was assembled in a drop tower apparatus and then cyclically loaded from 230–4300N at 1 Hz for a total of 2,000 cycles. The applied load was oriented at 25° to the trunnion axis in the frontal plane and 10° in the sagittal plane. The displacement of the head relative to the trunnion during cyclic loading was measured by a three-camera digital image correlation (DIC) system. The same loading conditions were simulated using the FEA model using the optimal value of µ derived from the initial head assembly trials.INTRODUCTION
MATERIALS and METHODS
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
Mechanically-assisted corrosion of the head-neck junction present a dilemma to surgeons at revision THR whenever the femoral component is rigidly fixed to the femur. Many remove the damaged femoral head, clean the femoral taper and fix a new head in place to spare the patient the risks associated with extraction and replacement of the well-functioning femoral stem. This study was performed to answer these research questions:
Will new metal heads restore the mechanical integrity of the original modular junction after impaction on corroded tapers? Which variables affect the stability of the new interface created at revision THR? Twenty-two tapers (CoCr, n=12; TiAlV, n=10) were obtained for use in this study. Ten stems were in pristine condition, while 12 stems had been retrieved at revision THR and with corrosion damage to the trunnion (Goldberg scale 4). Twenty-two new metal heads were obtained for use in the study, each matching the taper and manufacturer of the original component. The following test states were performed using a MTS Machine: 1. Assembly, 2. Disassembly, 3. Assembly, 4. Toggling and 5. Disassembly. All head assemblies were performed wet using 50% calf serum in accordance to ISO 7206-10. During toggling, each specimen's loading axis was aligned 25° to the trunnion axis in the frontal plane and 10° in the sagittal plane (Figure 1). Toggling was performed at 1Hz for 2,000 cycles with a sinusoidal loading function (230N–4300N). During loading, 3D motion of the head-trunnion junction was measured using a custom jig rigidly attached to the head and the neck of each prosthesis. Relative displacement of the head with respect to the neck was continuously monitored using 6 high resolution displacement transducers with an accuracy of ±0.6µm. Displacement data was independently validated using FEA models of selected constructs.Introduction
Materials and Methods
Manifestation of high interface stresses coupled with micromotion at the interface can render the taper lock joint in a modular hip replacement prosthesis at risk for failure. Bending can lead to crevice formation between the trunnion and the head and can potentially expose the interface to the biological fluids, generating interface corrosion. Additionally, development of high stresses can cause the material to yield, ultimately leading to irreversible damage to the implant. The objective of this study is to elucidate the mechanical response of taper junction in different material combination assemblies, under the maximum loads applied during everyday activities. Computer simulations were executed using a verified FE model. A stable hexahedral mesh (33648 elements) was generated for the trunnion (taper size: 12/14mm) and a tetrahedral mesh (51182 elements) for the head (CoCr, size: 32mm). An assembly load of 4000N was applied along the trunnion axis followed by the application of a load of 230–4300N at 25° and 10° angle to the trunnion axis in the frontal and sagittal planes. A linear static solution was set up using Siemens NX Nastran. Two material combinations were tested - cobalt-chrome head with a titanium alloy trunnion and cobalt chrome head with a cobalt-chrome trunnion.Introduction
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:
Methods:
