Accuracy of finite element predictions on bone/implant interface contact pressures for models reconstructed from CT scans

Finite element (FE) simulations can be utilized to predict contact pressures at the bone/implant interface as well as to identify the position and shape of the contact region. However, the accuracy and reliability of FE models of the bone/implant interface reconstructed from tomographic images may be affected by a number of factors such as the presence of image artifacts, the magnitude of geometric errors made in the reconstruction process, the type of boundary and loading conditions hypothesized in the model, the nonlinear solver utilized for computing the contact pressure distribution, and the element type. This paper attempts to estimate the global effect of the aforementioned factors. For this purpose, a cylindrical contact problem - pin/muff portraying a simplified model of the bone/implant interface is considered. The accuracy of numerical predictions is estimated by comparing contact pressures predicted by an FE model reconstructed from computed tomography (CT) scan images and by an ideal, experimentally validated FE model. Two different couplings, i.e. chromium-cobalt alloy and titanium implants, are considered. In the former case, image artifacts complicate the reconstruction process of model geometry and lead to less accurate predictions on contact pressure distribution; conversely, the limited streaking effects occurring in the titanium pin case allow us to precisely reconstruct coupling geometry. Finally, a rather clear correlation between errors on contact pressure and geometric errors made in the reconstruction process is found only for the titanium pin.