Bernd-Arno Behrens

Numerical investigations on the strain-adaptive bone remodelling in the periprosthetic femur: Influence of the boundary conditions

BackgroundThere are several numerical investigations on bone remodelling after total hip arthroplasty (THA) on the basis of the finite element analysis (FEA). For such computations certain boundary conditions have to be defined. The authors chose a maximum of three static load situations, usually taken from the gait cycle because this is the most frequent dynamic activity of a patient after THA.Materials and methodsThe numerical study presented here investigates whether it is useful to consider only one static load situation of the gait cycle in the FE calculation of the bone remodelling. For this purpose, 5 different loading cases were examined in order to determine their influence on the change in the physiological load distribution within the femur and on the resulting strain-adaptive bone remodelling. First, four different static loading cases at 25%, 45%, 65% and 85% of the gait cycle, respectively, and then the whole gait cycle in a loading regime were examined in order to regard all the different loadings of the cycle in the simulation.ResultsThe computed evolution of the apparent bone density (ABD) and the calculated mass losses in the periprosthetic femur show that the simulation results are highly dependent on the chosen boundary conditions.ConclusionThese numerical investigations prove that a static load situation is insufficient for representing the whole gait cycle. This causes severe deviations in the FE calculation of the bone remodelling. However, accompanying clinical examinations are necessary to calibrate the bone adaptation law and thus to validate the FE calculations.

Numerical investigations of stress shielding in total hip prostheses

Aseptic loosening of the prosthesis is still a problem in artificial joint implants. The loosening can be caused by, among other factors, resorption of the bone surrounding the prosthesis owing to stress shielding. In order to find out the influence of the prosthesis type on post-operative stress shielding, a static finite element analysis of a femur provided with the conventional uncemented stem BICONTACT and of one with the femoral neck prosthesis SPIRON was carried out. Strain energy densities and maximal principal strain distributions were calculated and compared with the physiological situation. Here, stress shielding was demonstrated in both periprosthetic femora. To determine the areas of the stress shielding, the bone in each FE model was subdivided into three regions of interest (ROI): proximal, diaphyseal, and distal. The numerical computations show stress shielding in the proximal ROI of both periprosthetic femora. Diaphyseally, the femoral neck prosthesis SPIRON, in contrast to the conventional uncemented long-stem prosthesis BICONTACT, causes no decrease in the strain distribution and thus no stress shielding. Distally, no change in the load distribution of either periprosthetic femur could be found, compared with the physiological situation.

Mechanical properties of femoral trabecular bone in dogs

BackgroundStudying mechanical properties of canine trabecular bone is important for a better understanding of fracture mechanics or bone disorders and is also needed for numerical simulation of canine femora. No detailed data about elastic moduli and degrees of anisotropy of canine femoral trabecular bone has been published so far, hence the purpose of this study was to measure the elastic modulus of trabecular bone in canine femoral heads by ultrasound testing and to assess whether assuming isotropy of the cancellous bone in femoral heads in dogs is a valid simplification.MethodsFrom 8 euthanized dogs, both femora were obtained and cubic specimens were cut from the centre of the femoral head which were oriented along the main pressure and tension trajectories. The specimens were tested using a 100 MHz ultrasound transducer in all three orthogonal directions. The directional elastic moduli of trabecular bone tissue and degrees of anisotropy were calculated.ResultsThe elastic modulus along principal bone trajectories was found to be 11.2 GPa ± 0.4, 10.5 ± 2.1 GPa and 10.5 ± 1.8 GPa, respectively. The mean density of the specimens was 1.40 ± 0.09 g/cm3. The degrees of anisotropy revealed a significant inverse relationship with specimen densities. No significant differences were found between the elastic moduli in x, y and z directions, suggesting an effective isotropy of trabecular bone tissue in canine femoral heads.DiscussionThis study presents detailed data about elastic moduli of trabecular bone tissue obtained from canine femoral heads. Limitations of the study are the relatively small number of animals investigated and the measurement of whole specimen densities instead of trabecular bone densities which might lead to an underestimation of Youngs moduli. Publications on elastic moduli of trabecular bone tissue present results that are similar to our data.ConclusionThis study provides data about directional elastic moduli and degrees of anisotropy of canine femoral head trabecular bone and might be useful for biomechanical modeling of proximal canine femora.

Flashless precision forging of a two-cylinder-crankshaft

Flashless precision forging is a special process of drop forging performed in closed dies. This process is distinguished by high quality and the ability to achieve a near net-shape part. Latest research results have shown that it is possible to forge a two-cylinder crankshaft without flash. This was realized using a multi-directional forging tool and a flashless precision forging operation. A new method for a three dimensional shrinking compensation facilitates the construction process.

Cross wedge rolling and bi-directional forging of preforms for crankshafts

AbstractPreforming is an essential step in flashless forging processes. This paper describes the development of a four stage process chain for flashless forging of a two cylinder crankshaft with pin and flange. The process consists of cross wedge rolling, lateral extrusion, bi-directional forging and final forming, with cross wedge rolling being the essential step. The finite-element-analysis (FEA) performed with the software Forge 3 and experimental tests are executed with different process parameters, like billet and tool temperature, rolling velocity and steel. To reduce process steps, like lateral extrusion, a direct combination of cross wedge rolling and bi-directional forging is analysed with FEA-software Forge 3 for a one cylinder crankshaft without pin and flange. The one cylinder crankshaft is selected to reduce development effort. The results of the FEA give suitable forming angles α for cross wedge rolling and several geometric parameters for a modification of the bi-directional tool.

Basic study on the process combination of deposition welding and subsequent hot bulk forming

Today most technical parts and components are made of monolithic materials. Nevertheless, the previously used monolithic materials reach their technological and constructive limits, so that an improvement of the component properties can be realized by hybrid parts. Forging of previously joined semi-finished products to net shape hybrid components is a promising method to produce functional adapted parts in a few process steps. This new process chain offers a number of advantages compared to other manufacturing technologies. Examples are the production of specific load-adapted forging parts with a high level of material utilization, an improvement of the joining zone caused by the followed forming process and an easy to implement joining process because of the simple geometries of the semi-finished products. This paper describes the production process of hybrid steel parts, which are produced by a combination of a deposition welding process with a subsequent hot forging (upsetting) or cross-wedge-rolling. It could be shown that the innovative process chain enables the production of hybrid parts whereby the forging processes lead to an improvement of the mechanical properties of the laser deposited material.

Advanced friction modeling for bulk metal forming processes

The finite element method is a powerful tool for the design and optimization of hot forming processes. In order to obtain high accuracy in simulation results, exact knowledge of the process conditions is required. Due to the fact that friction in the contact area has a significant impact on the material flow during the forming process, a realistic description of this boundary condition in the FE simulation is important for the usability of the simulation results. The most important influencing factors are the contact pressure, the roughness of the contact surfaces, the sliding velocity and the flow behavior of the material. Currently, only constant friction coefficients are considered in commercial finite element systems for the simulation of bulk metal forming processes. However, this description does not represent the state of the art in tribology. A new friction model is developed, taking into account the sliding velocity between tools and workpiece. This is confirmed by experimental and numerical investigations on model experiments and industrial process.

Numerical simulation of strain-adaptive bone remodelling in the ankle joint

BackgroundThe use of artificial endoprostheses has become a routine procedure for knee and hip joints while ankle arthritis has traditionally been treated by means of arthrodesis. Due to its advantages, the implantation of endoprostheses is constantly increasing. While finite element analyses (FEA) of strain-adaptive bone remodelling have been carried out for the hip joint in previous studies, to our knowledge there are no investigations that have considered remodelling processes of the ankle joint. In order to evaluate and optimise new generation implants of the ankle joint, as well as to gain additional knowledge regarding the biomechanics, strain-adaptive bone remodelling has been calculated separately for the tibia and the talus after providing them with an implant.MethodsFE models of the bone-implant assembly for both the tibia and the talus have been developed. Bone characteristics such as the density distribution have been applied corresponding to CT scans. A force of 5,200 N, which corresponds to the compression force during normal walking of a person with a weight of 100 kg according to Stauffer et al., has been used in the simulation. The bone adaptation law, previously developed by our research team, has been used for the calculation of the remodelling processes.ResultsA total bone mass loss of 2% in the tibia and 13% in the talus was calculated. The greater decline of density in the talus is due to its smaller size compared to the relatively large implant dimensions causing remodelling processes in the whole bone tissue. In the tibia, bone remodelling processes are only calculated in areas adjacent to the implant. Thus, a smaller bone mass loss than in the talus can be expected. There is a high agreement between the simulation results in the distal tibia and the literature regarding.ConclusionsIn this study, strain-adaptive bone remodelling processes are simulated using the FE method. The results contribute to a better understanding of the biomechanical behaviour of the ankle joint and hence are useful for the optimisation of the implant geometry in the future.

Integrative process chain optimization using a Genetic Algorithm

For the production of forged components, it is necessary to coordinate and optimize the production stages along the process chain. This includes the mainstream processes as well as the associated process chain of the die manufacturing. Up to now, these processes and process chains are planned and optimized independent from each other because of the different and often contradictory target criteria. In this paper, a new approach for a holistic optimization of forged process chains will be presented. At first, a systematic mathematical dependency-analysis between the processes of an application scenario was carried out. Based on this analysis, a holistic Pareto-based optimization of the process parameters by the use of a Genetic Algorithm was consecutively performed. The article ends with the presentation and discussion of the computational results.

Reduction of wear at hot forging dies by using coating systems containing boron

The near surface area of forging dies is exposed to high mechanical loads. Additionally thermal and chemical stresses appear during the hot forging process. Depending on the number of forged parts, several kinds of stresses occur in the near surface area, which lead to the initial failures of forging dies. Wear is the main reason for production downtimes with a ratio of 70%. Furthermore, thermal and mechanical cracks are typical causes for failures causes as well as plastic deformation. In order to reduce wear, the abrasion resistance of the forging die surface has to be increased. Hence, different methods like plasma nitriding and optional additional thin hard coatings (TiN, TiCN, TiC, TiBN and TiB2) were successfully examined. Recently developed Ti–B–N coatings in specific multilayer designs are thermally stable, wear-resistant and anti-adhesive regarding the sticking of work piece material. This paper presents the wear reduction possibilities of boron-containing multilayer coating systems applied to forging dies by using the plasma enhanced chemical vapor deposition treatment. A basic mechanical and analytical characterization of different coating systems is realized in the first stage of the project. Best qualified multilayer coating variants were applied to forging dies for experimental investigations. As a result of the tests, wear can be reduced significantly by using thermally stable boron multilayer coatings. To receive realistic wear values under production conditions, an automated forging process was used for testing. After 3,000 forged parts, the coatings were examined by tactile measurement, SEM and EDX analyses to characterize the occurring wear.