Finite Element Analysis and Computational Framework for Optimizing Laser Surface Modified Ti-6Al-4V Femoral...

Titanium alloys such as Ti-6Al-4V are widely used in orthopedic implants due to their strength and biocompatibility. Laser Surface Remelting (LSR) offers a promising approach to modify surface properties without altering bulk characteristics. This study investigates the effects of varying melt pool depths (MPDs) from 0 μm to 30 μm in 10 μm steps on the mechanical behavior of Ti-6Al-4V femoral components in Total Knee Replacement (TKR) using a comprehensive computational approach combining Finite Element Analysis (FEA) and computational algorithm-based automated evaluation. A three-dimensional FEA model was developed and tested under four physiological loading conditions: compression, axial distraction, medial bending, and lateral flexion at 1300 N. Results show that increasing MPD from 0 μm to 30 μm increases the maximum von Mises stress by 4.2% under compression but reduces displacement by up to 51.7% under distraction. An MPD of 20 μm reduces displacement by 48% while increasing stress by only 2.7%, representing an optimal balance. The computational algorithm framework identifies 15-25 μm as the optimal range for balancing surface enhancement with mechanical integrity. Experimental validation shows good agreement between simulated and measured results, confirming the reliability of the proposed framework for optimizing surface modification parameters in orthopedic implants.