Unrestricted Kinematic alignment (KA) in total knee arthroplasty (TKA) replicates the joint line of each patient by adjusting the cuts based on the anatomy of the patient. Mechanical alignment (MA) aims to restore a neutral mechanical axis of the leg, irrespective of the joint line orientation. The purpose of the present study was to compare contact pressure and contact areas of the polyethylene (PE) bearing surface as well as von Mises stress of the PE-tibial tray interface for MA and KA in the same patient, using CT data and finite element analysis. Finite element models were created from lower leg CT scans of 10 patients with knee osteoarthritis with different phenotypes. Mechanical PE properties were experimentally determined by tensile tests on dumbbell specimens. For numerical simulation purposes an adjusted non-linear material model with the maximum load to failure of 30.5 MPa, was calibrated and utilized. Contact pressure points were the deepest parts of the polyethylene inlay. Contact pressures were either very similar or were increased for MA knees throughout the gait cycle. KA either increased or had a comparable contact area, compared to MA. KA and MA produced comparable von Mises stresses, although both alignments breached the failure point of 30.5 MPa in all 3 valgus knees. This might indicate a higher probability of failure at the inlay-tibial baseplate interface. By maintaining the joint line orientation, KA reduces or has comparable contact pressures on the PE bearing surface by increasing or maintaining the contact area throughout one gait cycle in a validated finite element analysis model in 10 different knee phenotypes. The von Mises stress on the PE-tibial component interface was comparable, except for the valgus knees, where the load to failure was achieved in both alignment strategies and slightly higher stresses were observed for KA. Further studies for different knee phenotypes are needed to better understand the pressure changes depending on the alignment strategy applied.
Laminated composites with thermoset matrices are already well established in major engineering fields like automotive and aviation. The primary drawbacks of such thermoset-based composites are the high cycle times required during manufacturing and their limited potential for recycling. Providing an alternative to thermoset-based composites, thermoplastic matrix materials gained more and more momentum by addressing these previously mentioned drawbacks. The preferred manufacturing technique for these materials employs fiber-reinforced thermoplastic tapes consolidated and formed together with a compatible substrate. The most critical aspect for all these applications is the stress or load transfer between the thermoplastic tapes and the substrate. If the interface is too weak and fails prior to the substrate or tape, a high amount of theoretical mechanical performance is lost. The presented research investigates the influence of variations in manufacturing parameters, within the industrially relevant process window, on the interface strength of the final composite. The investigated composite material consists of PPGF UD tapes consolidated on a PPGF mat substrate. In particular, the influence of the consolidation parameters of pressure, temperature, and time are of special interest. The results of this work reveal a 400% increase in the measured mean strain energy release rate upon increasing the consolidation time from 60 s to 120 s at a consolidation temperature of 230 °C and a pressure of one bar. In contrast to this, an increase in the consolidation pressure, at constant temperature and time, leads to a minor improvement in the GC value of 20%. For testing and characterizing the corresponding interface properties, a mandrel peel testing setup was employed.
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