Influence of taper design and loading on taper micromotion

Debris originating at the bore-trunnion interface of modular total hip replacements has been identified as one of the causes of hip replacements failure. Friction associated with fretting and corrosion represents a potential generator of these harmful particles. Understanding the motions at the interface will help to interpret the different damage patterns found in retrieval studies and minimize the risk of fluid ingress/egress into the taper interface. Accordingly, the present study is designed to characterise the nature of the relative motions generated at the bore-trunnion interface of different taper designs during typical loading profiles. 3D Finite Element (FE) models of a CoCr femoral head assembled onto a Ti alloy trunnion were generated and variables including taper clearance, deviation from roundness, assembly force and loading conditions were introduced. Resulting micromotions relative to the trunnion surface, separation and contact area of the bore-trunnion interface were shown to be affected by both taper design and types of activities. Results indicated that, in some cases, the largest component of motion corresponded to that developed normal to the trunnion surface. Furthermore, out of roundness as small as 6 μm across the diameter, in particular orientations, significantly changed the contact mechanics and magnitude of relative motions. From the resulting parameters at the bore-trunnion interface, a pump type of motion was identified during walking, jogging and stairs up activities. The components of relative motions at the bore-trunnion interface were found to be different regardless of the resultant magnitude of the relative motions. The findings highlight the importance of high-quality manufacturing processes as small changes in the trunnion component will significantly affect the clinical performance of this common type of modular approach in total hip replacements.