External fixation is widely used in the fixation of fractures and limb deformities. The mechanical characteristics of a specific external fixator are major factors in determining the biomechanical environment at a fracture/osteotomy site and, hence, affect the healing process. Although the optimal biomechanical environment for healing of a fracture or an osteotomy is unknown, a specific range of interfragmentary motion exists which promotes healing. It is therefore desirable that the mechanics of an external fixator can be manipulated to enable the surgeon to control the range of interfragmentary motion. The characteristics of an external fixator are defined by a large number of variables. Therefore, to gain control over the degree of interfragmentary motion, an understanding of the effect of each variable and how it interacts with the others to determine the overall characteristics of the device is required. For the past two decades, individual components and whole-frame configurations have been studied in depth. This article provides a summary of previous work concerning the mechanics of external ring fixators and how they affect the biomechanical environment at the fracture/osteotomy site.
This study demonstrates that clamping a tensioned wire can cause a reduction in wire tension. Tension (about 1275 N) was applied to a wire that was subsequently clamped, using cannulated bolts, to the steel half-ring of an Ilizarov external fixator. The tension in the wire was monitored before, during and after clamping. The apparatus was disassembled and the deformations in the wire caused by the clamps were measured. This experiment was repeated 15 times. When the wire was clamped to the frame, the wire tension was reduced by 22 +/- 7 per cent (mean +/- standard deviation, SD). The drop in wire tension was linearly correlated (r = 0.96; p < 0.001) with the deformation caused by the bolts. A finite element (FE) model of the wire was also constructed. The model was pre-stressed (tensioned), and the clamping effect replicated. This analysis showed that clamping the wire could be considered to squeeze the wire outwards (like toothpaste from a tube) and so reduce its tension during fixator assembly. To assess the magnitude of this effect in the clinical situation, the FE model analysis was repeated to replicate clamping a 1.8-mm-diameter wire to a 180-mm-diameter steel Ilizarov ring component. The analysis showed that for these conditions the tension reduced by 8-29 per cent. The results of this study highlight a general engineering problem: how can a tensioned wire be secured to a structure without an appreciable loss of tension? If the performance of the structure depends on the wire tension, this performance will change when the wire is secured.
This study demonstrates that the clamped-wire system used to suspend bones within an Ilizarov external fixator yields when the perpendicular load exceeds 50 N per wire. Cyclic loading was applied to tensioned wires clamped within an Ilizarov ring component, with steadily increasing load amplitude. Wires were tested at four initial tension settings. The amount of energy lost within the clamped-wire system per load cycle was calculated for every test. The results showed that there was a consistent trend to increasing non-recoverable energy loss per load cycle when peak loads exceed 50 N for all initial tension settings. A finite element (FE) model replicating the experimental conditions was performed to investigate the levels of stress within the loaded wires. The FE model analyses showed that high stresses were generated in the wires close to the clamping sites, and that the stress levels could reasonably be expected to exceed the material yield stress when loaded to about 55 N, for all initial tension settings. The results show that material yield, accompanied by some wire slippage through the clamps, is responsible for system yield, in agreement with previous studies. Although the initial wire tension has an appreciable effect on the wire stiffness, it did not affect the elastic load range of the clamped-wire system. To prevent yield of the clamped-wire system in practice, the fixator should be assembled with sufficient wires to ensure that the load transmitted to each wire by the patient does not exceed 50 N.
This study describes a computational method for predicting the mechanical response of any configuration of the Ilizarov external fixation system. Mechanical testing of each of the individual components (ring, threaded rod, and wire) of the Ilizarov system was used to determine the stiffness of each component. Finite element (FE) analysis was then used to model each of the individual components. Each model was tuned to match the mechanical testing. A modular FE modelling system, using a master input file, was then developed where the tuned FE models of the individual components could be generated, positioned, and interconnected to replicate a range of fixator configurations. The results showed that the stiffness predications from the FE modelling of the fixator configurations were consistently 10 per cent higher than the stiffness values obtained from the mechanical testing. The FE modelling system can be used to predict the characteristic response of the fixator configurations and clearly shows the relative changes in that response for variations in the number of components used.
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