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ROLLING CONTACT ORTHOPAEDIC JOINT DESIGN by Alexander Henry

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ROLLING CONTACT ORTHOPAEDIC JOINT DESIGN by Alexander Henry ROLLING CONTACT ORTHOPAEDIC JOINT DESIGN by Alexander Henry Slocum, Jr. S.M., Mechanical Engineering, Massachusetts Institute of Technology, 2010 S.B., Mechanical Engineering, Massachusetts Institute of Technology, 2008 Submitted to the Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in Mechanical Engineering at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY February 2013 © 2013 Massachusetts Institute of Technology, All Rights Reserved Author:_______________________________________________________________________ Alexander H. Slocum, Jr. Department of Mechanical Engineering January 11, 2013 Certified by:___________________________________________________________________ Prof. Kripa K. Varanasi Associate Professor of Mechanical Engineering Thesis Supervisor and Committee Chair Accepted by:___________________________________________________________________ David E. Hardt Professor of Mechanical Engineering Chairman, Department Committee on Graduate Students ROLLING CONTACT ORTHOPAEDIC JOINT DESIGN by Alexander Henry Slocum, Jr. Submitted to the Department of Mechanical Engineering on January 11 th , 2013 in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in Mechanical Engineering Abstract Arthroplasty, the practice of rebuilding diseased biological joints using engineering materials, is often used to treat severe arthritis of the knee and hip. Prosthetic joints have been created in a “biomimetic” manner to reconstruct the shape of the biological joint. We are at a disadvantage, however, in that metals and polymers used to replace bone and articular cartilage often wear out too soon, leading to significant morbidity. This thesis explores the use of kinetic-mimicry, instead of bio-mimicry, to design prosthetic rolling contact joints, including knee braces, limb prosthetics, and joint prostheses, with the intent of reducing morbidity and complications associated with joint/tissue failure. A deterministic approach to joint design is taken to elucidating six functional requirements for a prosthetic tibiofemoral joint based on anatomical observations of human knee kinetics and kinematics. Current prostheses have a high slide/roll ratio, resulting in unnecessary wear. A rolling contact joint, however, has a negligible slide/roll ratio; rolling contact prostheses would therefore be more efficient. A well-established four-bar linkage knee model, in a sagittal plane that encapsulates with the knee’s flexion/extension degree of freedom, is used to link human anatomy to the shape of rolling cam surfaces. The first embodiment of the design is a flexure coupling-based joint for knee braces. Failure mode analysis, followed by cyclic failure testing, has shown that the prototype joint is extremely robust and withstood half a million cycles during the first round of tests. Lubrication in the joint is also considered: micro- and nano-textured porous coatings are investigated for their potential to support the formation of favorable lubrication regimes. Hydrodynamic lubrication is optimal, as two surfaces are separated by a fluid gap, thus mitigating wear. Preliminary results have shown that shear stress is reduced by more than 60% when a coating is combined with a shear thinning lubricant like synovial fluid. These coatings could be incorporated into existing joint prostheses to help mitigate wear in current technology. This thesis seeks to describe improvements to the design of prosthetic joints, both existing and future, with the intent of increasing the overall quality of care delivered to the patient. Thesis Supervisor: Kripa K. Varanasi Title: Doherty Associate Professor of Mechanical Engineering 2 Doctoral Thesis Committee Thesis Supervisor and Committee Chair: Kripa K. Varanasi, PhD Doherty Associate Professor of Mechanical Engineering Massachusetts Institute of Technology Martin L. Culpepper, PhD Associate Professor of Mechanical Engineering Massachusetts Institute of Technology Douglas P. Hart, PhD Professor of Mechanical Engineering Massachusetts Institute of Technology Just Herder, PhD Associate Professor of Mechanical and Biomechanical Engineering TU Delft, The Netherlands 3 This work is dedicated to Bubsi, Marianna, Pat and John Through this their memory lives on! 4 ACKNOWLEDGEMENTS I am indebted to my creator, in whatever form that may be, for giving me the skill of mind and hand used to execute this work My wife, Sarah Slocum (7) SB ‘11, the patience, love, and support you have shown me from day one have made me a better man. I have gotten more out of a class that I dropped than any other endeavor I have ever pursued. Now that this is finished, I’m truly all yours and I look forward to growing old with you. Also thanks to Mara and Rex. My parents, Alexander H. Slocum, Sr. (2) SB ’82, SB ’83, PhD ‘85 and Debra L. T. Slocum (6) SM ’88, for giving me life, teaching me to finish the things that I start, instilling in me both a strong work ethic and the will to succeed, and for showing me the world. Joshua (6) SB ‘10, SM ’11, and Jonathan Slocum (2) SB ’14 – a man could not ask for better brothers. You both have grown into fine men and it is so awesome to see you succeeding. Marianna P. Slocum, (8) SB '55, (18) SM '58 – you told me to never let anyone tell me I couldn’t do something, and I listened. I love you grandma, and I miss you very much. John and Patricia Thurston – Grandma and Grandpa Buffy, you were my inspiration to keep playing the piano. The dexterity and determination I developed will enable me to achieve my dreams. I love you both, and you are missed. Richard W. Slocum, Jr., (Gramps) (8), SB ’55, PhD ’58 – for all those times we went flying together, and our adventures at scout camp. Also, Spirulina! The following is a list of individuals with whom I interacted during the course of this work, and to whom I am grateful: Prof. Lalit Anand, MIT – for his advice and guidance regarding brittle fracture analysis, presented in Chapter 4, Section 4.4.1. Esther Austin, MIT – for her infinite knowledge and for helping me to navigate my time as a nonresident student. Eric Blough, Marshall – for engaging me during the summer and fall of 2011, and allowing me to work in his laboratory on parts of chapter 6. Dr. Mary Bouxsein and Dr. Margaret Seton, HMS – instructors for the IAP 2011 course HST.021 “Musculoskeletal Pathophysiology”. This was my first introduction to the field of orthopaedics; thank you for allowing me to take this course as it served me well during the initial stages of this thesis, and even later during medical school. Brian Brown, RCBI - for laser cutting and fabrication work at the Robert C. Byrd Institute for Advanced Flexible Manufacturing. Dr. Dennis Burke, MGH – for allowing me to observe him in the operating room performing total knee and total hip replacements, and giving me advice on the synthesis of the joint. Tom Cervantes, MIT – one of my UROP students, he helped design the rolling contact testing apparatus used to evaluate the adjustable bone plates, presented as the case study in Chapter 3. 5 Yuehua Cui, MIT – for her guidance and advice on the fabrication of etched and anodized porous coatings, and for her time and efforts in helping Jad and Daniel when I was not there. Prof. Marty Culpepper, MIT – a member of my committee, and my master’s thesis advisor, for your time, thoughts, and guidance over the past 5 years, during which time I have learned a lot from you. I hope to work with you again the future. Tom Dolan – of Dolan’s Welding and Steel Fabrication, for his fantastic laser cutting services and for fabricating the first prototype rolling contact joint. Jad El-Khoury, MIT – one of my UROP students, for his time, dedication, and willingness to learn, and for running countless numbers of lubrication experiments Andrew Gallant, MIT – of the MIT Central Machine Shop, for the excellent, professional service and outstanding product. Central Machine fabricated the components for the passive alignment mechanism used to conduct tribological experiments, and also polished all of the coupons. Prof. Lorna J. Gibson, MIT – taught the spring 2011 course 3.595 – Mechanics of Porous Media, where the ideas on elastic averaging were developed; this became the first half of Chapter 6. Daniel Goodman, MIT – one of my first UROP students, for helping me to design the rheological testing apparatus, for helping me get the first images of the porous coatings, Dr. Rajiv Gupta, MGH – my mentor for my bachelor’s thesis, he helped me to discover my passion for the field of medicine. Dr. Julio Guerrero, DRAPER – a close friend, long-time mentor and advisor. I learned much from you during our time at Schlumberger together. Pierce Hayward, MIT – for his assistance with the Instron used to evaluate the adjustable bone plates, and the white light interferometer. Prof. Doug Hart, MIT – a member of my committee, for your time, thoughts and guidance regarding lubrication and for helping me figure out which experiments to run now and in the future to adequately characterize lubrication. Prof. Just Herder, TU Delft – I can honestly say that without that conversation on April 15 th , 2008, this thesis would most likely not exist. Thank you for your input and advice on this work, and I hope we can continue to collaborate in the future. Dr. Jonathan Hopkins – One of my old lab mates and now a post-doc at LLNL. He pointed out the importance of shear angle in analyzing the slip condition discussed in Chapter 4, Section 4.3.2. Jon also wrote section 5.5. Aditya Jaishankar, MIT – Aditya is a brilliant doctoral student in the Microfluidics laboratory working on rheology of lubricants like synovial fluid, and I am grateful for his time, guidance and expertise in operating the rheometer as well as for all things lubricant-related! Christopher Love, MIT – one of my lab mates, and previously one of my teammates in the Spring 2008 class 2.782, Design of Medical Devices and Implants, and for which I proposed the idea of designing a rolling contact joint for knees.
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