Fast Detection of Heat Accumulation in Powder Bed Fusion Using Computationally Efficient Thermal Models.

The powder bed fusion (PBF) process is a type of Additive Manufacturing (AM) technique which enables fabrication of highly complex geometries with unprecedented design freedom. However, PBF still suffers from manufacturing constraints which, if overlooked, can cause various types of defects in the final part. One such constraint is the local accumulation of heat which leads to surface defects such as melt ball and dross formation. Moreover, slow cooling rates due to local heat accumulation can adversely affect resulting microstructures. In this paper, first a layer-by-layer PBF thermal process model, well established in the literature, is used to predict zones of local heat accumulation in a given part geometry. However, due to the transient nature of the analysis and the continuously growing domain size, the associated computational cost is high which prohibits part-scale applications. Therefore, to reduce the overall computational burden, various simplifications and their associated effects on the accuracy of detecting overheating are analyzed. In this context, three novel physics-based simplifications are introduced motivated by the analytical solution of the one-dimensional heat equation. It is shown that these novel simplifications provide unprecedented computational benefits while still allowing correct prediction of the zones of heat accumulation. The most far-reaching simplification uses the steady-state thermal response of the part for predicting its heat accumulation behavior with a speedup of 600 times as compared to a conventional analysis. The proposed simplified thermal models are capable of fast detection of problematic part features. This allows for quick design evaluations and opens up the possibility of integrating simplified models with design optimization algorithms.

A modal derivatives enhanced Rubin substructuring method for geometrically nonlinear multibody systems.

This paper presents a novel model order reduction technique for 3D flexible multibody systems featuring nonlinear elastic behavior. We adopt the mean-axis floating frame approach in combination with an enhanced Rubin substructuring technique for the construction of the reduction basis. The standard Rubin reduction basis is augmented with the modal derivatives of both free-interface vibration modes and attachment modes to consider the bending-stretching coupling effects for each flexible body. The mean-axis frame generally yields relative displacements and rotations of smaller magnitude when compared to the one obtained by the nodal-fixed floating frame. This positively impacts the accuracy of the reduction basis. Also, when equipped with modal derivatives, the Rubin method better considers the geometric nonlinearities than the Craig-Bampton method, as it comprises vibration modes and modal derivatives featuring free motion of the interface. The nonlinear coupling between free-interface modes and attachment modes is also considered. Numerical tests confirm that the proposed method is more accurate than Craig-Bampton's, a nodal fixed floating frame counterpart originally proposed in Wu and Tiso (Multibody Syst. Dyn. 36(4): 405-425, [2016]), and produces significant speed-ups. However, the offline cost is increased because the mean-axis formulation produces operators with decreased sparsity patterns.

Fracture risk and initial fixation of a cementless glenoid implant: the effect of numbers and types of screws.

The initial fixation of an anatomical cementless glenoid component, provided by different numbers and types of screws, and the risk of bone fracture were evaluated by estimating the bone-implant interface micromotions and the principal strains around the prosthesis. Four different fixation configurations using locking or compression screws were tested. Estimation of the micromotions at the bone-implant interface was performed both experimentally, using an in vitro model, and computationally, using a numerical model. Principal bone strains were estimated using the numerical model. Subject variability was included by modelling two different bone qualities (healthy and rheumatoid bone). For the fixation configurations that used two screws, experimental and modelling results found that the micromotions at the bone-implant interface did not change with screw type. However, screw type had a significant effect on fixation when only one screw was used; in this case, a locking screw resulted in less micromotion at the bone-implant interface compared with the compression screw. Bone strains were predicted by the numerical model, and strains were found to be independent of the screw type; however, the predicted strain levels calculated in rheumatoid bone were larger than the strain levels that may cause bone damage for most considered arm positions. Predicted bone strain in healthy bone did not reach this level. While proper initial component fixation that allows biological fixation can be achieved by using additional screws, the risk of bone failure around the screws must be considered, especially in cases of weak bone.

Interface micromotions increase with less-conforming cementless glenoid components.

BACKGROUND: The optimal degree of conformity between the glenoid and humeral components in total shoulder arthroplasty for best performance and durability is still a matter of debate. The main aim of this study is to evaluate the influence of joint conformity on the bone-implant interface micromotions in a cementless glenoid implant. MATERIALS AND METHODS: Polyethylene inlays with different degrees of conformity (radial mismatch of 0, 2, 4, and 6 mm) were mounted on a cementless metal back and then implanted in a bone substitute. These glenoid components were loaded by a prosthetic humeral head during a force-controlled experiment. Normal-to-interface micromotions and bone substitute deformations were measured at different points of the interface. Rim displacement and humeral head translation were also measured. A finite element (FE) model of the experiments was implemented to estimate the normal- and tangent-to-interface micromotions in the entire bone-implant interface. RESULTS: All measured variables increased with less-conforming PE inlays. Normal-to-interface micromotions were significantly larger (P < .05) when the radial mismatch was 6 mm compared with the fully conforming inlay. The FE model was in agreement and complemented the experimental results. FE model-predicted interface micromotions were already significantly larger when the radial mismatch was equal to 4 mm. DISCUSSION: In a force-controlled experiment with a cementless glenoid component, a non-conforming PE inlay allows larger interface micromotions than a conforming inlay, reaching a magnitude that may hamper local bone ingrowth in this type of component. This is mainly because of the larger humeral head translation that boosts the effects of the so-called rocking-horse phenomenon.

Bone remodelling around a cementless glenoid component.

Post-operative change in the mechanical loading of bone may trigger its (mechanically induced) adaptation and hamper the mechanical stability of prostheses. This is especially important in cementless components, where the final fixation is achieved by the bone itself. The aim of this study is, first, to gain insight into the bone remodelling process around a cementless glenoid component, and second, to compare the possible bone adaptation when the implant is assumed to be fully bonded (best case scenario) or completely loose (worst case scenario). 3D finite element models of a scapula with and without a cementless glenoid component were created. 3D geometry of the scapula, material properties, and several physiological loading conditions were acquired from or estimated for a specific cadaver. Update of the bone density after implantation was done according to a node-based bone remodelling scheme. Strain energy density for different loading conditions was evaluated, weighted according to their frequencies in activities of daily life and used as a mechanical stimulus for bone adaptation. The average bone density in the glenoid increased after implantation. However, local bone resorption was significant in some regions next to the bone-implant interface, regardless of the interface condition (bonded or loose). The amount of bone resorption was determined by the condition imposed to the interface, being slightly larger when the interface was loose. An ideal screw, e.g. in which material fatigue was not considered, was enough to keep the interface micromotions small and constant during the entire bone adaptation simulation.

Effect of rotator cuff dysfunction on the initial mechanical stability of cementless glenoid components.

The functional outcome of shoulder replacement is related to the condition of the rotator cuff. Rotator cuff disease is a common problem in candidates for total shoulder arthroplasty; this study relates the functional status of the rotator cuff to the initial stability of a cementless glenoid implant. A 3D finite element model of a complete scapula was used to quantify the effect of a dysfunctional rotator cuff in terms of bone-implant interface micromotions when the implant is physiologically loaded shortly after surgery. Four rotator cuff conditions (from fully intact to progressively ruptured rotator cuff tendons) as well as two bone qualities were simulated in a model. Micromotions were significantly larger in the worst modeled cuff dysfunction (i.e. the supraspinatus and infraspinatus tendons were fully dysfunctional). Micromotions were also significantly different between conditions with healthy and poor bone quality. The implant's initial stability was hardly influenced by a dysfunctional supraspinatus alone. However, when the infraspinatus was also affected, the glenohumeral joint force was displaced to the component's rim resulting in larger micromotions and instability of the implant.

Prediction of torsional failure in 22 cadaver femora with and without simulated subtrochanteric metastatic defects: a CT scan-based finite element analysis.

BACKGROUND: In metastatic bone disease, prophylactic fixation of impending long bone fracture is preferred over surgical treatment of a manifest fracture. There are no reliable guidelines for prediction of pathological fracture risk, however. We aimed to determine whether finite element (FE) models constructed from quantitative CT scans could be used for predicting pathological fracture load and location in a cadaver model of metastatic bone disease. MATERIAL AND METHODS: Subject-specific FE models were constructed from quantitative CT scans of 11 pairs of human femora. To simulate a metastatic defect, a transcortical hole was made in the subtrochanteric region in one femur of each pair. All femora were experimentally loaded in torsion until fracture. FE simulations of the experimental set-up were performed and torsional stiffness and strain energy density (SED) distribution were determined. RESULTS: In 15 of the 22 cases, locations of maximal SED fitted with the actual fracture locations. The calculated torsional stiffness of the entire femur combined with a criterion based on the local SED distribution in the FE model predicted 82% of the variance of the experimental torsional failure load. INTERPRETATION: In the future, CT scan-based FE analysis may provide a useful tool for identification of impending pathological fractures requiring prophylactic stabilization.

A finite-element analysis model of orbital biomechanics.

To reach a better understanding of the suspension of the eye in the orbit, an orbital mechanics model based upon finite-element analysis (FEA) has been developed. The FEA model developed contains few prior assumptions or constraints (e.g., the position of the eye in the orbit), allowing modeling of complex three-dimensional tissue interactions; unlike most current models of eye motility. Active eye movements and forced ductions were simulated and showed that the supporting action of the orbital fat plays an important role in the suspension of the eye in the orbit and in stabilization of rectus muscle paths.

Controlling incision-induced distortion of nasal septal cartilage: a model to predict the effect of scoring of rabbit septa.

Cartilage can be shaped by scoring. In an exploratory study in living adult animals, this phenomenon was demonstrated in cartilage of the nasal septum. Bending was observed immediately after superficial scoring of the cartilage surface, and the cartilage always warped in the direction away from the scored side. The scored piece of cartilage still showed its initially distorted shape 10 weeks after primary surgery. In ex vivo experiments, a clear relation between incision depth and bending of septal cartilage was observed. Under these controlled conditions, the variation between different septa was small. Deformation of the septal specimens was increased by introducing single superficial incisions deepening to half the thickness of the cartilage. A positive correlation between incision depth and bending was demonstrated. A model was used to accurately predict the degree of bending of the cartilage after making an incision of a particular depth. Hence, the effect of cartilage scoring can be predicted. Because the results of this controlled study showed excellent reproducibility for different septa, it is expected that this model can be extrapolated to human nasal septum cartilage. This would enable the surgeon to better predict the result of cartilage scoring, either preoperatively or perioperatively.