This paper investigates the mechanical response of a modular head-neck interface of hip joint implants under realistic loads of level walking. The realistic loads of the walking activity consist of three dimensional gait forces and the associated frictional moments. These forces and moments were extracted for a 32mm metal-on-metal bearing couple. A previously reported geometry of a modular CoCr/CoCr head-neck interface with a proximal contact was used for this investigation. An explicit finite element analysis was performed to investigate the interface mechanical responses. To study the level of contribution and also the effect of superposition of the load components, three different scenarios of loading were studied: gait forces only, frictional moments only, and combined gait forces and frictional moments. Stress field, micro-motions, shear stresses and fretting work at the contacting nodes of the interface were analysed. Gait forces only were found to significantly influence the mechanical environment of the head-neck interface by temporarily extending the contacting area (8.43% of initially non-contacting surface nodes temporarily came into contact), and therefore changing the stress field and resultant micro-motions during the gait cycle. The frictional moments only did not cause considerable changes in the mechanical response of the interface (only 0.27% of the non-contacting surface nodes temporarily came into contact). However, when superposed with the gait forces, the mechanical response of the interface, particularly micro-motions and fretting work, changed compared to the forces only case. The normal contact stresses and micro-motions obtained from this realistic load-controlled study were typically in the range of 0-275MPa and 0-38µm, respectively. These ranges were found comparable to previous experimental displacement-controlled pin/cylinder-on-disk fretting corrosion studies.

A finite element model was developed to investigate the effect of loading regimes caused by various daily activities on the mechanical behaviour of the head-neck taper junction in modular hip replacements. The activities included stair up, stair down, sit to stand, stand to sit, one leg standing and knee bending. To present the real mechanical environment of the junction, in addition to the force components, the frictional moments produced by the frictional sliding of the head and cup were applied to a CoCr/CoCr junction having a 12/14 taper with a proximal mismatch angle of 0.024°. This study revealed that stair up with the highest fretting work per unit of length (1.62 × 104J/m) was the most critical activity, while knee bending and stand to sit with 1.96 × 103J/m were the least critical activities. For all the activities, the superolateral region of the neck was identified as the most critical region in terms of having larger values of fretting work per unit of area. This study showed also that the relative micro-motions and contact stresses occurring at the head-neck interface for all the studied activities are mostly in the range of 0-38µm and 0-350MPa, respectively. These ranges may be accordingly employed for conducting relevant in-vitro tests to more realistically represent the mechanical environment of taper junctions with the same materials and geometry studied in this work.