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The Effect of Counterface Roughness On The Wear of UHMWPE For Rectangular Wear Paths
The Effect of Counterface Roughness On The Wear of UHMWPE For Rectangular Wear Paths
P(2A)
P(2A + 2B)
A
k =
V
M.E. Turell et al. / Wear 259 (2005) 984991 985
duced annually [7,8], which continues to be the primary con-
cern in total hip replacement prostheses. The accumulation
of particulate debris in the peri-prosthetic tissue can elicit a
biological response leading to bone loss (osteolysis) and im-
plant loosening, necessitating complicated revision surgery
to replace the implant [911].
Osteolysis associated with particulate wear debris has
prompted numerous investigations, which study the size,
shape and morphology of particulate debris and the biolog-
ical pathway that leads to particle-induced osteolysis. Wear
debris collected from peri-prosthetic tissue retrieval studies
showed that the majority of debris particles associated with
hip replacement prostheses were micron or sub-micron in size
and that particles could generally be categorized as brous or
particulate in shape [1216]. Particulate wear also occurs in
total knee replacement (TKR) components, although the par-
ticle size distribution differs from that of total hip replacement
(THR) wear particles, and TKR particles have been shown to
be generally larger than THR wear particles [17].
Computational and experimental studies have shown that
multi-directional motion or cross-shear motion can affect
wear rate of UHMWPE in total hip and total knee replace-
ments [18,19]. Linear tracking motion, whether unidirec-
tional or reciprocating produces an extremely low wear rate,
and in fact produces two to three orders of magnitude less
wear than is observed clinically in total knee replacement
prostheses [1924]. The higher clinical wear rates of total
knee replacement prostheses can be attributed to both coun-
terface scratching [25,26] as well as the effects of cross-shear
motion. Wang et al. have proposed that in a wear environ-
ment, UHMWPE macromolecules orient preferentially along
the principal direction of sliding [19,2224]. Unlike in lin-
ear tracking, where orientation results in strain hardening of
surface material and ultimately increases wear resistance as
sliding progresses, in multi-directional motion, the wear sur-
face experiences both compressive and shear forces in mul-
tiple directions. As sliding proceeds, the UHMWPE wear
surface may strengthen along the direction of sliding, while
it weakens in the perpendicular direction. It has been demon-
strated that the loci or trajectory of motion at the contact
point between a femoral head of an orthopaedic implant and
an acetabular cup is a quasi-ellipse or an approximate rectan-
gle during a gait cycle [18,19,27]. Some patients have either
more elongated (approximately rectangular) or more closed
(approximately more square-like) motion patterns than oth-
ers [27]. Examples of elongated and closed motion patterns
traced by the contact point between femoral and acetabular
components are illustrated in the examples shown in Fig. 1.
Bennett et al. have postulated that the differences in motion
patterns affect the in vivo wear rates of UHMWPE acetabular
cups in patients where factors such as age, weight and body
proportion were similar, but gait patterns varied widely [27].
The multi-directional sliding, or orientation-softening
wear model, proposed by Wang has been termed the unied
theory of wear for UHMWPE [28]. This theory proposed
that when a femoral head slides against an acetabular cup
Fig. 1. Elongated motion pattern (left) and closed motion pattern (right)
traced by the contact point between the formal and acetabular components
of orthopaedic implants.
along the wear path dened by the rectangular loop, fric-
tional energy is dissipated in both the A and B directions (see
Fig. 1). Since A < B, B denes the principal direction of slid-
ing motion while A is secondary. Previous studies indicated
that motion in the principal sliding direction, B, leads to plas-
tic deformation or macromolecular orientation whereas mo-
tion in the secondary direction, A, leads to material removal
by fracture [19,2224,28]. Therefore, only energy released
in the A direction is directly responsible for wear [28]. The
expression for wear rate can then be expressed as:
V mP(2A) (1)
where V is volumetric wear rate, is the coefcient of fric-
tion, P is the applied normal load and 2A is the sliding dis-
tance in the secondary direction per cycle. Since the wear
coefcient or wear factor, k, is dened as (volumetric wear
rate)/(load total sliding distance), in the case of a rectan-
gular wear path illustrated above, k can be written as:
A + B
(2)
Eq. (2) theoretically quanties the effect of cross-path mo-
tion on the wear factor of UHMWPE. In a previous set of
experiments, we compared wear factors for UHMWPE artic-
ulated in a series of graded wear paths in which the aspect
ratio of the wear path was systematically increased. These
wear tests were conducted using a cobaltchromium articula-
tion surface with an implant-grade smooth nish. The results
showed that the wear factors from these experiments were in
agreement with the proposed model only at high aspect ra-
tios, i.e. wear factors were found to signicantly decrease in
the rectangular wear path with the highest aspect ratio and in
linear tracking [29]. A question that remains to be answered
is whether the proposed model remains valid under condi-
tions of abrasive wear. Studies have shown that the addition
of bone cement (with zirconium and barium sulfate additives)
and bone particles to test serum lubricant produces signi-
cantly greater surface damage to stainless steel articulation
counterfaces which in turn results in surface roughening and
increased wear rates [25]. Similarly, other authors have found
that roughening of the femoral head, to a degree seen typically
in retrieval specimens, can increase the observed variability
of volumetric wear rates approximately seven-fold. This fact
may explain why random femoral head scratching in vivo
accounts for otherwise difcult to explain variations in wear
rates as abrasive wear may be a key factor causing excessive
wear in the most problematic subset of the patients with to-
986 M.E. Turell et al. / Wear 259 (2005) 984991
tal joint replacements [26]. The purpose of the current study
is to determine whether the unied theory of wear is appli-
cable to conditions of abrasive wear, such as the case of a
roughened counterface articulating against UHMWPE along
rectangles of various aspect ratios. It was hypothesized that
under conditions of abrasive wear, the model would in gen-
eral describe the cross-path wear of UHMWPE as accurately
as it had under conditions in which a smooth counterface was
employed.
2. Materials and methods
2.1. UHMWPE starting material
Commercially available, ram-extruded GUR 1050
(Hoechst-Ticona, Bayport, TX) rod stock (PolyHi Solidur,
Ft. Wayne, IN) was used as the starting material for all wear
tests. Rod stock with a diameter of 7.6 cm was machined into
cylindrical pins with overall dimensions of 20 mm in length
and 9 mm in diameter for all wear tests. All pins were tested
in the as-machined condition (no sterilization).
2.2. Wear testing protocol and apparatus
A series of six different articulation patterns including
a 5 mm 5 mm square, 4 mm 6 mm, 3 mm 7 mm,
2 mm 8 mm, and 1 mm 9 mm rectangles, and a
0 mm 10 mm linear tracking pattern were digitized
into an OrthoPOD
TM
(Advanced Mechanical Technology
Inc.) multi-directional wear tester. For each wear test, the
OrthoPOD
TM
multi-directional wear tester was loaded
with six UHMWPE pins as shown in the experimental
set-up in Fig. 2. All wear tests were conducted at a cycle
frequency of 1 Hz (constant sliding speed of 20 mm/s along
the wear track) and with a constant applied load of 192 N
or an applied stress of 3 MPa, well within the physiological
range of 25 MPa for the hip joint. A bovine serum (JRH
Biosciences) lubricant was used for all wear tests, and
was diluted with distilled water to contain 23 g/L protein,
20 mM EDTA, and 0.2% sodium azide. The lubricating
bovine serum temperature was maintained at 37
C using
a re-circulating water bath. Cobaltchromium disks with
dimensions of 25 mm diameter and 3 mm thickness were
used as the articulation counterface. Two series of wear tests
using each of the six experimental articulation patterns were
performed. In one series of tests, cobaltchromium disks
were polished to implant-grade surface smoothness with
a centerline roughness of 0.015 m (Ra). In a second set
of experiments, the cobaltchromium disks were scratched
along random directions using 320 grit emery paper in
accordance with the previously established method of Wang
et al., resulting in an average roughness, Ra, of 0.45 m
[30]. A total of six pins plus an additional pin serving as a
soak control were used for all wear tests.
2.3. Data analysis
Wear rates for each of the six articulation patterns were
determined in experiments in which both smooth and rough
counterfaces were employed. Gravimetric weight loss per pin
was determined approximately every 200,000 cycles. The
soak control consistently revealed that the amount of absorp-
tion of bovine serum by the UHMWPE specimen was unde-
tectable and therefore any corrections to compensate for uid
absorption were unnecessary. For each group, wear tests were
Fig. 2. AMTI OrthoPOD
TM
multi-directional wear tester.
M.E. Turell et al. / Wear 259 (2005) 984991 987
continued until at least one million cycles had been reached.
The gravimetric weight loss per pin was determined by taking
the average weight loss of the six wear tested pins. Prior to
being weighed, UHMWPE pins were rst washed twice with
distilled water followed by an alcohol and acetone rinse, re-
spectively. The pins were dried in air at 25
6E08
(
R
=
0
.
8821)
A + B
+
4E07
(
R
=
0
.
9922)
M.E. Turell et al. / Wear 259 (2005) 984991 989
tions about some of the underlying assumptions upon which
the model is based. For example, for any rectangular wear
path with sides A and B, where A < B, the model assumes
that orientation on the molecular level occurs in the B di-
rection, while fracture, or the actual wearing of UHMWPE,
occurs in the A direction. Based on the results of this study, in
which wear reached a maximum for the 3 mm 7 mm wear
path, this assumption may not be a valid description of the
orientation and wear processes. It is possible that complete
orientation and strain hardening of UHMWPE in the B direc-
tion is required for wear to occur solely in the A direction,
and that this is only achieved at 7 mm of sliding. It is there-
fore possible that for the 5 mm 5 mm and 4 mm 6 mm
wear paths, there is signicant reorientation in the A direc-
tion as well rather than fracture of the fully oriented, strain
hardened UHMWPE brils. Reorientation would imply that
a different wear mechanism is operative since biaxial ori-
entation prior to wear would suggest that a more sheet-like
material wears rather than splitting of brillar UHMWPE.
These wear and orientation mechanisms appeared to occur in
two discrete A/(A + B) ranges, irrespective of the roughness
of counterface.
Fig. 6 shows that there was a linear correlation between
wear factor, k, and the numerical parameter A/(A + B), regard-
less of counterface roughness. The linear equations for these
correlations as well as the R-values (to measure the degree of
t) were obtained for both the smooth and rough counterface
tests. In the equation for the line, k = m[A/(A + B)] + c, the
constant c (y-intercept) represents the fraction of wear factor
that is due to linear, abrasive wear and the constant m (slope)
is a measure of the dependence of cross-path wear on the
wear path geometry. The following equations were obtained
for the linear correlations:
k = 7E06
A
(smooth counterface) (3)
k = 1E05
A
(rough counterface) (4)
It is evident that the constant c cannot assume a negative
value, and the low, negative wear factor value of 6E08
for linear tracking for smooth heads obtained from the lin-
ear t is merely a consequence of experimental error, which
can be taken to be zero or replaced by the experimentally
measured positive value of 5.06E08. The value of m was
higher in the rough counterface series of wear tests. The
ratio of mrough/msmooth was 1.4, revealing that there was a
steeper dependence of wear factor, k, on the numerical pa-
rameter, A/(A + B), in the case of rough counterface. For both
the smooth and rough counterface, the high R-values indi-
cated a strong linear correlation between the wear factor and
A/(A + B). The good t of the wear factors in the series of
wear paths in the range of 0 mm 10 mm to 3 mm 7 mm
paths suggests that complete orientation followed by frac-
ture of brils was the primary mechanism of wear in both
of these cases. Independent of the accuracy with which the
model investigated in this paper predicted wear rate, the over-
all experimental results support the hypothesis that wear rate
is in fact dependent upon the wear path geometry, counterface
roughness and the interplay of these two variables.
4.2. Clinical relevance
The nding that wear rate is dependent upon both wear
path pattern and counterface roughness has a number of clin-
ically relevant implications. The observation that differences
in wear rates, between tests employing rough versus smooth
counterfaces, are greater in more linear motion path patterns
and that these differences systematically decrease as the wear
approaches a square pattern is an important nding. In total
joint replacement applications where linear wear is known to
be operative and to have a signicant impact upon the life-
time of the joint replacement, for example, as is the case in
the knee joint, the effects of abrasive wear (simulated by a
roughened counterface in this study) are of greater concern.
It should be noted that the results of this study reveal a some-
what oversimplication of the wear mechanisms as they oc-
cur in clinical application since the effects of third body wear
and fatigue-related wear mechanisms were not investigated.
A question which remains to be answered is whether it may
be possible to predict motion path patterns by conducting
gait analysis and if so, whether motion path pattern can be
therapeutically manipulated using methods of gait training or
by making improvements to implant design. A challenge in
addressing these questions lies in the difculty in assessing
gait in patients who require total joint replacement surgery
as gait in these individuals may be altered from their normal
baseline gait due to the orthopaedic complications, which ne-
cessitate surgery in the rst place. Similarly, gait patterns in
these individuals may be dramatically altered following total
joint replacement surgery, making it difcult to predict the
effects of implant design in advance of surgery.
4.3. Limitations
The results of this study represent an attempt to quantify
the effect of the motion path pattern and counterface rough-
ness on wear rate of UHMWPE. It should be noted that the
data, in particular the wear factor values, that have been ana-
lyzed in this paper represent the results of preliminary wear
tests conducted for each wear path geometry to a period of at
least one million cycles. A more comprehensive study, and
one that would employ more rigorous wear testing would
generate a larger number of samples for tests encompassing
a broader range of motion path patterns. From such experi-
ments, trends in the values of UHMWPE wear rates would
be more reliably generated and would be of a greater level
of clinical signicance. A study of the morphology of wear
990 M.E. Turell et al. / Wear 259 (2005) 984991
particles generated from the various motion path patterns for
both smooth and rough counterface tests is also necessary
(and forthcoming) to obtain a more accurate understanding
of the wear mechanisms that are operative during the various
wear paths. In addition, the wear tests in this paper employed
a constant applied load and it is important for future studies
to include wear test loading parameters which more closely
model the loading conditions found in knee and hip joints
in vivo. The relationship between wear path and wear rates
established in this study applies only to uncrosslinked med-
ical grade UHMWPE. Further wear testing on the various
crosslinked UHMWPEs currently in clinical use is required
for such relationships to be established.
5. Conclusions
Wear of UHMWPE as it articulates against a metallic
counterface in a particular wear path and under conditions
that mimic wear in a total hip replacement prosthesis, likely
occurs via two discrete steps for rectangles with an aspect
ratio greater than 2.33 (3 mm 7 mm rectangular path). For
such rectangles, the wear tests of this study support the hy-
pothesis that there is orientation or texturing of UHMWPE
on parallel edges of the rectangle followed by wear of the
textured UHMWPE on the other two parallel edges. How-
ever, for rectangles in the aspect ratio range of 1.02.33
(5 mm 5 mm to 4 mm 6 mm paths), the decline in wear
rates for both smooth and rough counterface experiments
provide evidence that wear and orientation processes may
not occur in discrete stages. In addition, the unied wear
model predicts zero wear for linear tracking, which is not
the case, especially when more abrasive conditions of wear
occur such as the case of a roughened counterface. A more
robust model is required to predict wear of UHMWPE during
articulation against a metallic counterface along a rectangu-
lar path covering the entire range of aspect ratios of rectan-
gles.
Acknowledgments
This project was funded through a biomedical engineering
grant provided by the Whitaker Foundation and by a fellow-
ship provided by the Orthopaedic Research and Education
Foundation.
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