Optimization of WSU Total Ankle Replacement Systems

Wright State University CORE Scholar Browse all Theses and Dissertations Theses and Dissertations 2012 Optimization of WSU Total Ankle Replacement Systems Bradley Jay Elliott Wright State University Follow this and additional works at: https://corescholar.libraries.wright.edu/etd_all Part of the Biomedical Engineering and Bioengineering Commons Repository Citation Elliott, Bradley Jay, "Optimization of WSU Total Ankle Replacement Systems" (2012) Browse all Theses and Dissertations 578 https://corescholar.libraries.wright.edu/etd_all/578 This Thesis is brought to you for free and open access by the Theses and Dissertations at CORE Scholar It has been accepted for inclusion in Browse all Theses and Dissertations by an authorized administrator of CORE Scholar For more information, please contact library-corescholar@wright.edu Optimization of WSU Total Ankle Replacement Systems A thesis submitted in partial fulfillment of the requirements for the degree of Master of Science By Bradley Jay Elliott B.S., Wright State University, 2010 2012 Wright State University WRIGHT STATE UNIVERSITY GRADUATE SCHOOL June 26, 2012 I HEREBY RECOMMEND THAT THE THESIS PREPARED UNDER MY SUPERVISION BY Bradley Jay Elliott ENTITLED Optimization of WSU Total Ankle Replacement Systems BE ACCEPTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF Master of Science in Engineering Tarun Goswami, D.Sc Thesis Director David B Reynolds, Ph.D Assistant Chair, Department of Biomedical, Industrial, & Human Factors Engineering Committee on Final Examination Tarun Goswami, D.Sc David B Reynolds, Ph.D Richard T Laughlin, M.D Mary E Fendley, Ph.D Andrew T Hsu, Ph.D Dean, Graduate School ABSTRACT Elliott, Bradley Jay, M.S.Egr Department of Biomedical, Industrial, and Human Factors Engineering, Wright State University, 2012 Optimization of WSU Total Ankle Replacement Systems Total ankle arthroplasty (TAR) is performed in order to reduce the pain and loss of ambulation in patients with various forms of arthritis and trauma Although replacement devices fail by a number of mechanisms, wear in the polyethylene liner constitutes one of the dominating failure modes This leads to instability and loosening of the implant Mechanisms that contribute to wear in the liners are high contact and subsurface stresses that break down the material over time Therefore, it is important to understand the gait that generates these stresses Methods to characterize and decrease wear in Ohio TARs have been performed in this research This research utilizes finite element analysis of WSU patented total ankle replacement models From the FEA results, mathematical models of contact conditions and wear mechanics were developed These models were used to determine the best methods for wear characterization and reduction Furthermore, optimization models were developed based on geometry of the implants These equations optimize geometry, thus congruency and anatomical simulations for total ankle implants iii TABLE OF CONTENTS I INTRODUCTION II BACKGROUND A ANKLE JOINT ANATOMY B GAIT C ANKLE BIOMECHANICS D ANKLE JOINT TRAUMA AND DISEASE 12 E EVOLUTION OF TOTAL ANKLE REPLACEMENT MODELS 16 LITERATURE REVIEW 20 A TAR EFFICACY 20 AGILITY 21 STAR 22 BP (BUECHEL-PAPPAS) 23 HINTEGRA 25 OTHERS 26 REVISION MODES 26 III B STRESS AND PRESSURE IN TAR UHMWPE BEARINGS 29 FEA OF CONTACT AND SUBSURFACE STRESSES 30 EXPERIMENTALLY DETERMINED CONTACT STRESSES 37 TAR ALIGNMENT AND CONTACT STRESSES 37 C UHMWPE IN TARS 38 PROPERTIES 39 WEAR RATE 40 iv D MATHEMATICAL CHARACTERIZATION IV V VI VII 42 HERTZIAN CONTACT 42 ARCHARD’S WEAR LAW 43 MATERIAL AND METHODS 44 A GAIT FORCES 44 B FINITE ELEMENT MODELING 48 VISCOELASTIC PARAMETERS 60 C MATHEMATICAL WEAR MODELING 64 MAXIMUM CONTACT PRESSURE WITH HERTZIAN CONTACT 64 ARCHARD’S LAW AND FRETTING WEAR 66 D STRESS OPTIMIZATION 67 RESULTS 68 A FINITE ELEMENT ANALYSIS 68 B MATHEMATICAL WEAR MODELING 85 STRESS OPTIMIZATION 88 AVERAGE SURFACE STRESS 88 MAXIMUM SURFACE STRESS 92 MAXIMUM CROSS SECTIONAL STRESS 95 AVERAGE CROSS SECTIONAL STRESS 100 STRESS DEPTH 105 FINAL OPTIMIZATION PARAMETERS 109 DISCUSSION 111 A FINITE ELEMENT ANALYSIS 111 B MATHEMATICAL ANALYSIS OF STRESS AND WEAR RATE 116 C OPTIMIZATION OF WSU TARS 117 iii VIII CONCLUSIONS 119 IX APPENDIX 121 X REFERENCES 135 iv LIST OF FIGURES Bones and Joints of Ankle Complex Motions of the Ankle Joints Ankle Joint Stresses During Stance Phase of Gait 11 Comparison of the Tensile Strength of Hip and Ankle Cartilage With Respect to Age 12 Fracture of the Fibular Malleolus 14 Ankle Joint Fused With Fixation Screws 15 First generation unconstrained TAR (left); First generation contrained TAR (right) 17 Examples of Fixed Bearing TAR (Left - Agility by Depuy Inc.) and mobile bearing TAR (Right – STAR by Small Bones Innovations Inc.) 18 Agility Total Ankle Replacement 21 10 Scandinavian Total Ankle Replacement 22 11 BP Total Ankle Replacement 23 12 HINTEGRA Total Ankle Replacement 25 13 Graph of Failure Mechanisms 27 14 Contact pressures for each gait position (Agility – top, Mobility – bottom) 31 15 Contact stresses in Agility TAR 33 16 Contact stresses at various points during the gait cycle 35 17 Subsurface stresses in various TKR liners 36 18 Creep Strain and Relaxation vs Time 39 19 Mathematically determined ankle joint force waveform by Seireg and Arvikar 45 20 Axial force waveform 45 21 Axial load with respect to percentage of gait at 866.4 N bodyweight 46 iv 22 Actual axial force waveform overlayed with approximate axial gait waveform 47 23 Implant Design M1 Solid Model 49 24 Implant Design M2 Solid Model 49 25 Implant Design M3 Solid Model 50 26 Implant Design N1 Solid Model 50 27 Implant Design N2 Solid Model 51 28 Implant Design N3 Solid Model 51 29 Implant Design N4 Solid Model 52 30 M1 articulating surface area, AS 53 31 M1 force application area, AF 53 32 M1 condylar arcs (radius of curvature and angle of curvature, θC) 54 33 M1 condylar arc length 54 34 M1 condyle mid-articulating length 55 35 Condylar thickness, TC, and cross-sectional area, AC 55 36 Example of boundary conditions for Model M2 58 37 125 kGy Crosslinked UHMWPE Creep Strain at 50° C 60 38 Normalized Shear Compliance for UHMWPE Data 63 39 Experimentally Determined UHMWPE Creep vs Predicted Creep 64 40 Maximum Mises Stress Model: M1 Material: Ti6Al4V 69 41 Maximum Mises Stress Model: M1 Material: CoCr 69 42 Maximum Mises Stress Model: M1 Material: Stainless Steel 70 43 Maximum Mises Stress Model: M2 Material: Ti6Al4V 70 44 Maximum Mises Stress Model: M2 Material: CoCr 71 45 Maximum Mises Stress Model: M2 Material: Stainless Steel 71 46 Maximum Mises Stress Model: M3 Material: Ti6Al4V 72 47 Maximum Mises Stress Model: M3 Material: CoCr 72 48 Maximum Mises Stress Model: M3 Material: Stainless Steel 73 iii 49 Maximum Mises Stress Model: N1 Material: Ti6Al4V 73 50 Maximum Mises Stress Model: N1 Material: CoCr 74 51 Maximum Mises Stress Model: N1 Material: Stainless Steel 74 52 Maximum Mises Stress Model: N2 Material: Ti6Al4V 75 53 Maximum Mises Stress Model: N2 Material: CoCr 75 54 Maximum Mises Stress Model: N2 Material: Stainless Steel 76 55 Maximum Mises Stress Model: N3 Material: Ti6Al4V 76 56 Maximum Mises Stress Model: N3 Material: CoCr 77 57 Maximum Mises Stress Model: N3 Material: Stainless Steel 77 58 Maximum Mises Stress Model: N4 Material: Ti6Al4V 78 59 Maximum Mises Stress Model: N4 Material: CoCr 78 60 Maximum Mises Stress Model: N4 Material: Stainless Steel 79 61 Model M1 Mises Stresses Through Gait Cycle 79 62 Model M2 Mises Stresses Through Gait Cycle 80 63 Model M3 Mises Stresses Through Gait Cycle 80 64 Model N1 Mises Stresses Through Gait Cycle 81 65 Model N2 Mises Stresses Through Gait Cycle 81 66 Model N3 Mises Stresses Through Gait Cycle 82 67 Model N4 Mises Stresses Through Gait Cycle 82 68 Average cross-sectional stresses through the width of the liners 83 69 Maximum cross-sectional stresses through the width of the liners 83 70 Contact Pressure at Maximum Point 84 71 Comparison of Contact Pressure for 2nd Generation Ohio TARs 85 72 Maximum Predicted Contact Pressure 86 73 Actual vs Predicted Average Surface Mises Stress 88 74 Average Mises Stress vs Articulating Surface Area 89 75 Average Surface Mises Stress vs Condylar Angle of Curvature 90 76 Average Surface Mises Stress vs Force Application Area 91 iv Figure 120: Maximum Cross-Sectional Mises Stress Model: N2 Material: CoCr Figure 121: Maximum Cross-Sectional Mises Stress Model: N2 Material: Stainless Steel 131 Figure 122: Maximum Cross-Sectional Mises Stress Model: N3 Material: Ti6Al4V Figure 123: Maximum Cross-Sectional Mises Stress Model: N3 Material: CoCr 132 Figure 124: Maximum Cross-Sectional Mises Stress Model: N3 Material: Stainless Steel Figure 125: Maximum Cross-Sectional Mises Stress Model: N4 Material: Ti6Al4V 133 Figure 126: Maximum Cross-Sectional Mises Stress Model: N4 Material: CoCr Figure 127: Maximum Cross-Sectional Mises Stress Model: N4 Material: Stainless Steel 134 X REFERENCES Saltzman C L., Salaman M L., Blanchard G M., Huff T., Hayes A., Buckwalter J A., Amendola A., Epidemiology of Ankle Arthritis: Report of a Consecutive Series of 639 Patients from a Tertiary Orthopaedic Center, Iowa Orthopaedic Journal, (2005) 25; 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Innovations Inc.) 18 Agility Total Ankle Replacement 21 10 Scandinavian Total Ankle Replacement 22 11 BP Total Ankle Replacement 23 12 HINTEGRA Total Ankle Replacement 25 13 Graph of Failure Mechanisms... Bradley Jay Elliott ENTITLED Optimization of WSU Total Ankle Replacement Systems BE ACCEPTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF Master of Science in Engineering Tarun... Jay, M.S.Egr Department of Biomedical, Industrial, and Human Factors Engineering, Wright State University, 2012 Optimization of WSU Total Ankle Replacement Systems Total ankle arthroplasty (TAR)