A combined experimental and finite element model study was carried out for an internal fixation plate configuration. The experimental model was an aluminum tube (bending stiffness equal to the human femur) plated using a titanium alloy (Ti-6Al-4V) plate. The model was subjected to a four-point flexural test and strains were measured with strain gauges mounted at the midplane of the tube and plate. One-, two-, and three-dimensional finite element models were generated of the experimental model and various loads were applied including the actual flexural test values. Experimental and finite element model strain results were compared allowing evaluation of the three types of finite element models commonly used for orthopedic stress analyses. Results of this study indicated that three-dimensional models should be utilized for analysis of screw stresses or contact stresses, but one-dimensional models are equivalent to two-dimensional models in less complex areas. Screw stress analysis indicated that the outermost screws are most likely to fail between the tube (bone) and plate. Shear stress levels at the screw-tube (bone) interface were also determined. Reduction of tube (bone) stress levels on the plated side of the tube suggest that plated bone in this area could become weakened during remodeling subsequent to initial fracture healing. Results of this study indicate the validity of a combined experimental and finite element approach for biomechanical analyses of internal fixation devices.
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