Donald L. Bartel

COULOMB FRICTIONAL INTERFACES IN MODELING CEMENTED TOTAL HIP REPLACEMENTS: A MORE REALISTIC MODEL

Loosening of cemented femoral hip stems could be initiated by failure of the cement mantle due to high cement stresses. The goals of this study were to determine if realistic stem-cement interface characteristics could result in high cement stresses when compared to a bonded stem-cement interface and to determine if stem design parameters could be chosen to reduce peak cement stresses. Three-dimensional finite-element models of cemented femoral hip components were studied with bonded or realistic Coulomb friction stem-cement interfaces. The results showed that the use of a non-bonded, non-linear Coulomb friction interface resulted in substantially different stress fields in the cement when compared to a bonded stem-cement interface. Tensile stresses in the proximal cement mantel for the Coulomb friction interface case (10.8 MPa) were greater than the fatigue strength of the cement. In contrast, the tensile stresses in the cement mantle were not greater than the fatigue strength for the bonded case (7.5 MPa). Failure of the cement mantle in the proximal femur could therefore be initiated by a lack of a bond at the stem-cement interface. The effect of different cross-sectional stem geometries (medial radii of 3.0, 4.9 and 5.5 mm and antero-posterior widths of 9.8 and 13.7 mm) and different elastic moduli (cobalt chromium alloy and titanium alloy) for the stem material were also evaluated for models with a Coulomb friction interface. Changes in the stem cross-section and elastic modulus had only limited effects on the stress distributions in the cement. Of the parameters evaluated in this study, the characteristics of the stem-cement interface had the largest effect on cement mantle stresses.

Surgical Variables Affect the Mechanics of a Hip Resurfacing System

Recent clinical studies have linked failure to surgical variables of stemmed hip resurfacing systems. We used finite element analysis to investigate the effects of implant position, stem orientation, and extent of fixation both on the local stresses and strains associated with implant loosening, neck fracture, and stem fracture, as well as on the load transfer distribution in the bone-implant system. The range of peak stress in the cement was reduced from 11 to 13 MPa for the varus stem to 3.2 to 4.2 MPa for the valgus stem. The range of peak strain in the bone was also reduced from −0.35% to −0.45% strain for the varus stem to −0.19% to −0.27% strain for the valgus stem, but only when reamed cancellous bone remained exposed. Peak stresses in the stem were low for all cases. Additionally, the implants load transfer distribution was generally insensitive to all variables examined and the femoral head was substantially unloaded. Our data indicate the local stresses and strains associated with implant loosening and neck fracture were reduced by placing the implant in a valgus orientation and covering reamed cancellous bone, but unloading of the femoral head, found for all variables examined, may lead to adverse bone remodeling.

Cemented femoral stem performance. Effects of proximal bonding, geometry, and neck length.

The effects of proximal bonding, distal stem geometry, and femoral neck length on cement and interface stresses were determined to understand better their role in clinical performance. The effects of stem design were compared with the effects of environmental variables, patient weight, and patient activity. Finite element models were used to determine peak cement and interface stresses, and an experimental layout was used to separate design and environmental effects. Bonding reduced cement mantle stresses by 35% to 60%, to levels below the cement fatigue strength. A flat sided implant provided more torsional resistance, reducing shear stresses at the proximal cement-prosthesis interface by 22% to 73% with respect to a distal round implant. Neck length had minimal effects on stresses compared with bonding or implant geometry. Cement-bone interface stresses were more sensitive to patient activity than to the design variables. Therefore, claims that a strong cement and prosthesis bond may be harmful to the bone-cement interface are unjustified based on these results. The best combination of design variables was a proximally bonded, flat sided implant with neck length left to the surgeons discretion. This combination was most effective at protecting the cement mantle and prosthesis interface and perhaps the cement-bone interface by minimizing stresses associated with cement debris generation.

Effects of porous coating, with and without collar support, on early relative motion for a cementless hip prosthesis

In theory, porous or rough coatings could be used to reduce early post-operative relative motion about cementless hip prostheses. To investigate this theory, we used detailed, non-linear finite element analysis to compare early relative motion about a well-fit Anatomical Medullary Locking (AML) prosthesis for different amounts of porous coating (full, proximal 2/3, and no coating), both with and without collar support. Details of the model included quantitative computed tomography-derived (QCT-derived) geometric and material properties for the bone, and a no-tension interface condition at all bone-prosthesis interfaces, with Coulomb friction (mu = 1.73) over coated surfaces and zero friction elsewhere. Predicted values of relative motion for this well-fit device were in the range of approximately 1-550 microns. The distribution of relative motion was relatively insensitive to the amount of porous coating but was sensitive to collar support, while the magnitude of relative motion was sensitive to the porous coating and collar support. In addition, a reduction in the porous coating caused larger increases in relative motion when there was no collar support, indicating an interaction between the effects of porous coating and collar support. For example, distal twist increased (full vs 2/3 partial coating) by 38% with collar support and by 58% without collar support. These data suggest that porous coating, or other surface treatments which result in a high coefficient of friction at the bone-prosthesis interface, may well be used to control the magnitude of early relative motion, particularly when there is no collar support.

The role of backside polishing, cup angle, and polyethylene thickness on the contact stresses in metal-backed acetabular components

Mechanical interactions between the polyethylene liner and the metal-backing play an important role in the load transfer and debris-generation mechanisms of an acetabular component. Insert thickness, cup orientation, and insert-shell interface conditions affect the resulting contact stresses at the articulating and backside surfaces of the polyethylene component. The objective of this study was to determine the variation in contact stresses on a hemispherical acetabular component as a function of the friction coefficient of the line-shell interface, the thickness of the insert, and the load application angle. Three-dimensional finite element models of a metal-backed acetabular component with liner thicknesses of 3-12 mm were developed. The insert-shell interface was modeled as either matte or highly polished, and the load angle of the joint reaction force was changed from 36 to 63 degrees with respect to the dome. We found that the contact stresses at the articulating and backside surfaces of the insert were relatively insensitive to changes in the coefficient of friction at the insert-shell interface (resulting in approximately 1-10% variation in contact stress), when compared to the effect of changing the inserts thickness (approximately 80% variation in contact stress) or changing the direction of the joint reaction force (approximately 20% variation in contact stress). The results of this study suggest that polishing the metal at the insert-shell interface does not substantially change the contact stresses at either surface of the component. Of the design variables available for selective modification by either the surgeon or the engineer, insert thickness and shell orientation play a greater role in determining the magnitude of the resulting contact stresses.

Design and Analysis of Robust Total Joint Replacements: Finite Element Model Experiments With Environmental Variables

Computer simulation of orthopaedic devices can be prohibitively time consuming, particularly when assessing multiple design and environmental factors. Chang et al. (1999) address these computational challenges using an efficient statistical predictor to optimize a flexible hip implant, defined by a midstem reduction, subjected to multiple environmental conditions. Here, we extend this methodology by: (1) explicitly considering constraint equations in the optimization formulation, (2) showing that the optimal design for one environmental distribution is robust to alternate distributions, and (3) illustrating a sensitivity analysis technique to determine influential design and environmental factors. A thin midstem diameter with a short stabilizing distal tip minimized the bone remodeling signal while maintaining satisfactory stability. Hip joint force orientation was more influential than the effect of the controllable design variables on bone remodeling and the cancellous bone elastic modulus had the most influence on relative motion, both results indicating the importance of including uncontrollable environmental factors. The optimal search indicated that only 16 to 22 computer simulations were necessary to predict the optimal design, a significant savings over traditional search techniques.

Effects of porous coating and collar support on early load transfer for a cementless hip prosthesis.

We used a new postprocessing method with the results from a three-dimensional finite element analysis to describe the general load transfer patterns for a cementless hip arthroplasty in the early postoperative situation, and to determine the effects of porous coating [full, partial (2/3), and none] and calcar-collar support (ideal initial contact with separation allowed upon loading, no collar) on this early load transfer. No-tension interfaces were modeled over the entire bone-prosthesis interface, with an upper bound on the Coulomb-friction over coated surfaces, and zero friction over smooth surfaces to accentuate the frictional effects of the coating. The results indicate that the anteroposterior, mediolateral, and axial forces acting on each cross section of the bone were substantially different from the corresponding homeostatic (no prosthesis) forces for the fully coated device with collar support. The frontal bending moments acting on the bone were substantially less than the homeostatic values all along the prosthesis, while the sagittal bending and torsional loads were relatively similar to the homeostatic values. By far, the largest change in these loading patterns occurred with the loss of collar support, where axial loads acting on the bone were so low that over half the bone was in net tension because appreciable transfer of the compressive head force did not occur until well below the lesser trochanter. Both axial and torsional loads were transferred more distally for devices with more coating, and torsional loading of the bone was also sensitive to the degree of collar support. The frontal bending moments acting over most of the bone were insensitive to the coating or collar support. The strain energy density in the endosteal bone was most sensitive to these design variables in the proximal region, and the largest values occurred without a collar and without coating. These findings indicate that all load components acting on the proximal bone in the early postoperative situation (no bone-ingrowth or fibrous tissue at the interface) are altered by the frictional coefficient of the bone-prosthesis interface (i.e. the presence of porous coating or some other surface treatment) and the degree of collar support, while only the axial and torsional loads are altered in the distal bone. From a prosthesis design perspective this implies that surface treatments and collar support can be used to control the axial forces and the torsional moments acting all along the bone. By contrast, the distal frontal bending moment, which dominates stresses in the diaphysis, cannot be altered by these design variables.

Prediction for Computer Experiments Having Quantitative and Qualitative Input Variables

This article introduces a Bayesian methodology for the prediction for computer experiments having quantitative and qualitative inputs. The proposed model is a hierarchical Bayesian model with conditional Gaussian stochastic process components. For each of the qualitative inputs, our model assumes that the outputs corresponding to different levels of the qualitative input have “similar” functional behavior in the quantitative inputs. The predictive accuracy of this method is compared with the predictive accuracies of alternative proposals in examples. The method is illustrated in a biomechanical engineering application.

Postirradiation aging affects stress and strain in polyethylene components

Ultrahigh molecular weight polyethylene components oxidatively degrade because of gamma radiation sterilization and subsequent shelf aging in air. The effects of shelf aging on the stresses and strains associated with surface damage in tibial and acetabular components were examined. A material model was developed to predict the stress and strain relationship of oxidatively degraded polyethylene as a function of density using samples of polyethylene that were gamma radiation sterilized and evaluated immediately after irradiation and after 42 months of shelf aging. The finite element method was used to determine the stresses and strains before and after shelf aging for two tibial components with different conformities between the articulating surfaces and for an acetabular component. The stresses increased by 10% to 14% in the conforming tibial model after 42 months of aging, whereas the stresses in the nonconforming tibial model and in the acetabular model increased by only 4% to 8%. Aging decreased the principal strains by 5% to 10% in both tibial models and by 15% to 17% in the acetabular model. Postirradiation aging during shelf storage of polyethylene joint components is likely to worsen long term wear, based on the increased stresses and decreased strains predicted to occur as a result of aging.

Wear simulation of the ProDisc-L disc replacement using adaptive finite element analysis

OBJECT An understanding of the wear potential of total disc replacements (TDRs) is critical as these new devices are increasingly introduced into clinical practice. The authors analyzed the wear potential of a ProDisc-L implant using an adaptive finite element (FE) technique in a computational simulation representing a physical wear test. METHODS The framework for calculating abrasive wear, first validated using a model of a total hip replacement (THR), was then used to model the ProDisc-L polyethylene component that is fixed to the inferior endplate and articulates with the rigid superior endplate. Proposed standards for spine wear testing protocols specified the inputs of flexion-extension (6/-3 degrees), lateral bending (+/- 2 degrees), axial twist (+/- 1.5 degrees), and axial load (200-1750 N or 600-2000 N) applied to the model through 10 million simulation cycles. The model was calibrated with a wear coefficient determined from an experimental wear test. Implicit FE analyses were then performed for variations in coefficient of friction, polyethylene elastic modulus, radial clearance, and polyethylene component thickness to investigate their effects on wear. RESULTS Using the initial loading protocol (single-peaked axial load profile of 300-1750 N) from the experimental wear test, the polyethylene wear rate was 9.82 mg per million cycles. When a double-peaked loading profile (600-2000 N) was applied, the wear rate increased to 11.77 mg per million cycles. Parametric design variations produced only small changes in wear rates for this simulation. CONCLUSIONS The chosen design variables had little effect on the resultant wear rates. The comparable wear rate for the THR validation analysis was 16.17 mg per million cycles, indicating that, using this framework, the wear potential of the TDR was equivalent to, if not better, than the THR using joint-specific loading standards.