Predicting long-term wear performance of hard-on-hard bearing couples: effect of cup orientation.

Wear is the major cause of implant failure, resulting in expensive revision surgeries of total hip arthroplasty. Therefore, understanding of wear mechanism and its progression is crucial to improve the physiological performance of implants. This paper presents a three-dimensional (3D) finite element (FE) wear modeling approach to estimate evolution of wear in hard-on-hard bearing components with the effect of cup abduction angle. Three bearing couples were considered, and they were PCD-on-PCD, Al2O3-on-Al2O3 and Si3N4-on-Si3N4, while the cup abduction angle varied from 35° to 70° with an increment of 5°. By adopting actual physiological hip gait loading and rotational movement for normal walking cycle in FE modeling, the contact pressure and the sliding distance were calculated to predict wear. A femoral head of 32 mm in diameter was considered, while a constant frictional contact at the inference between head and cup was used. During simulation, the geometry of cup surface was updated at a reasonable interval of gait cycles to consider the effect of wear. Wear was simulated for up to 20 million cycles which is an equivalent of 20 years of implant's life in human body. Simulation results showed that compared to other two bearing couples, the predicted linear and volumetric wear in PCD-on-PCD couple exhibited the least wear evolution for all cup angles considered. The increase in abduction angle from 35° to 70° decreases the volumetric wear by 28 % for all three bearing couples, due to the reduction in sliding distance. Steep cup angle, e.g., 70° for Al2O3 and Si3N4 bearing couples, encountered edge contact, which leads to more wear. Further, wear results were discussed and analyzed with respect to in vitro and/or clinical studies available in the literature to justify the efficacy of wear modeling.