Finite element analysis and optimization studies on tibia implant of SS 316L steel and Ti6Al4V alloy

Tibial fractures account for approximately 15% of all fractures, typically resulting from high-energy trauma. A critical surgical approach to treat these fractures involves the fixation of the tibia using a plate with minimally invasive osteosynthesis. The selection and fixation of the implant plate are vital for stabilizing the fracture. This selection is highly dependent on the plate's stability, which is influenced by factors like the stresses generated in the plate due to the load on the bone, as well as the plate's length, thickness, and number of screw holes. Minimizing these stresses is essential to reduce the risk of implant failure, ensuring optimal stress distribution and promoting faster, more effective bone healing. In the present work, the finite element and statistical approach was used to optimize the geometrical parameters of the implant plate made of SS 316L steel and Ti6Al4V alloy. A 3D finite element model was developed for analyzing the stresses and deformation, and implant plates were manufactured to validate the results with the help of an experiment conducted on the universal testing machine. A strong correlation was observed between the experimental and predicted results, with an average error of 8.6% and 8.55% for SS316L and Ti6Al4V alloy, respectively. Further, using the signal-to-noise ratio for the minimum stress condition was applied to identify the optimum parameters of the plate. Finally, regression models were developed to predict the stresses generated in SS316L and Ti6Al4V alloy plates with different input conditions. The statistical model helps us to develop the relation between different geometrical parameters of the Tibia implant plate. As determined by the present work, the parameter most influencing is implant plate length. This outcome will be used to select the implant for a specific patient, resulting in a reduction in implant failure post-surgery.