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Global Research journal of Natural Science

& Technology (GRJNST)

Volume: 04 - Issue 3 (2026), 2092

ISSN P: 2790-7643 ISSN E: 2790-7651

www.grjnst.net

https://doi.org/10.53762/grjnst.04.03.13

Management of Ti-6Al-4V and SS316L Stress Shielding and Stability of

Femoral Fracture Fixation Bone Plates by Finite Element Analysis in

COMSOL Metaphysics

Received: 21 March 2026. Accepted: 22 April 2026. Published: 22 May 2026

Kajal Dev

Institute of Biomedical Engineering and Technology,

Liaquat University of Medical and Health Sciences, Jamshoro, 76090, Pakistan

kajal.dev26@gmail.com

Hajira Fatima

Department of Biomedical Engineering,

Quaid-e-Awam University of Engineering, Science & Technology, Nawabshah 67480, Pakistan

hajirafatima@quest.edu.pk

Kashaf Khanzada

Institute of Biomedical Engineering and Technology,

Liaquat University of Medical and Health Sciences, Jamshoro, 76090, Pakistan

khanzadakashaf@gmail.com

Sehreen Moorat

Institute of Biomedical Engineering and Technology,

Liaquat University of Medical and Health Sciences, Jamshoro, 76090, Pakistan

sehreen.moorat@lumhs.edu.pk

Natasha Mukhtiar (Corresponding Author)

Institute of Biomedical Engineering and Technology,

Liaquat University of Medical and Health Sciences, Jamshoro, 76090, Pakistan

natasha.mukhtiar@lumhs.edu.pk

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Commons Attribution 4.0 International (CC BY 4.0) license, which permits unrestricted use and distribution

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Abstract:

The human femur is known as the longest bone in the human body. For

compression, it is known as the most robust bone. The femur bears the majority

of body weight and facilitates several essential functions, including ambulation

and leaping from a height. Bone fractures typically result from an excessive

stress that exceeds the maximum strain that a human bone can withstand. Due

to the loss of the bone's capacity for self-healing, a bone fracture with a

fragment larger than 5 mm needs extra support, such as a bone implant, for

recovery. The repair process is accelerated with a bone implant that holds the

parts in place, permits realignment, and limits excessive movement. The

commercially available bone plates comprised of biocompatible metallic

materials or metal alloys are used in the current fracture fixation technique. To

aid in the healing process, these bone plates are often attached to one side of the

fracture. Prosthetic bone bioimplants have been designed and developed using

conventional metallic biomaterials like titanium alloy (Ti-6Al-4V) and stainless

steel (SS 316L). Two typical internal fixation materials are relatively evaluated

with Finite Element Method (FEM) in COMSOL Multiphysics and they

comprise Titanium alloy (Ti-6Al-4V) and Stainless Steel (SS316L) in realistic

conditions of loads in the fractures of the diaphyseal segment of the femur. The

fixation of the fracture shall be stable and the issue of stress shielding is the

issue due to the use of the relatively inelastic material that is SS316L (Young)

which are the ones that bear the majority of the load and causes bone resorption

A complex 3D model of the femur-plate-screw system with transverse fracture

of 1 mm has been modeled with an intention of equaling the material with the

same physiological biomechanical boundary loads. These results showed that

theTi-6Al-4V plate system was in a superior state concerning the mechanical

performance of an overall displacement of 3.887599mm, compared to the huge

displacement of SS316L (25.1252). It proves that Ti-6Al-4V is better and

provides greater structural stability and thus is even more suitable material

which can be used as load-bearing orthopedic implants, where structural

stability is of significant determinant of clinical success.

Keywords: Femur fracture, Titanium alloy, Stainless Steel, Finite Element

Method

1. INTRODUCTION

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The human femur, as the longest and most robust bone in the skeletal system, plays a

critical role in supporting body weight, facilitating locomotion, and maintaining

structural integrity during dynamic activities. The femur has a long, slender and nearly

cylindrical structure of the body. The bottom (distal) part of the femur is bigger

compared to the top. It is composed of two oblong eminences referred to as condyles

(Das & Sarangi, 2014). The femur articulates with the socket at one end to create the

hip joint, while at the opposite end, it articulates with the tibia and patella to form the

knee joint. The most prevalent fracture that orthopedists deal with is the fracture of the

femoral shaft (Gösling & Krettek, 2019). Its incidence is 0.01% (Weiss et al., 2009). It

usually happens due to high energy traumas, and is linked to polytrauma, open fracture

and multiple fracture (Li et al., 2016). The predominant causes of femur fractures are

motor vehicle accidents, sports injuries, falls from significant heights, and pre-existing

bone conditions are common causes of it in young patients, and in old osteoporotic

patients (Gösling & Krettek, 2019; Weiss et al., 2009). That compromise bone

integrity, such as Paget's disease and osteoporosis (Ahirwar et al., 2021). Despite the

human femur's considerable resistance to fracture, it may sustain a break as a result of

high-velocity traumatic traumas. The biomedical implants have bone plates and other

materials that are applied to improve the physiological state of the victims of a road

accident and the elderly to enjoy normal lives (Kurniawan et al., 2022)

The bone fracture normally takes place when the corresponding stress is beyond what

human bone tissue can take. Once the bone no longer has the necessary capacity to heal

correctly, especially when the fracture gap or fragment size is more than 5 mm, some

mechanical assistance like a bone implant is necessary to help the bone heal correctly

(Kurniawan et al., 2022). A number of treatment approaches are widely applied when

working with the case of a broken femoral shaft, which includes skeletal traction, plate-

and-screw fixation, intramedullary nailing, and external fixation (Crist & Wolinsky,

2009; Scannell et al., 2010; Zlowodzki et al., 2007). When intramedullary fixation is

unable to be used effectively, plate fixation is usually suggested (Apivatthakakul et al.

2009; Köseoğlu et al., 2011). According to previous findings, material fatigue in the

fixation device has been cited as one of the major causes of internal fixation failure

(Birringer et al., 2016). Other studies have also examined the various plate-screw designs

in order to enhance stability and performance of the fixation. Bone implants can be used

to aid the healing process as they ensure that the fractured parts are stabilized so that the

bone can heal properly, and they help in limiting excessive movement during the healing

process (Cronier et al., 2010; Sheng et al., 2019; Wang et al., 2020).

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Biomechanics is a scientific field that applies technical principles of mechanics of all

forces acting on the human body and the impact of the forces on the bone to study the

biological system. It is a science that involves the application of mechanical principles to

an organism to gain insight behavior and mechanical behavior of biologic structures

(Ganesh et al., 2005). Biomechanical systems can be modelled and tested by using the

physics and engineering rules to investigate the performance of bones and other tissues

in terms of structure. The biomechanical factors, which dictate the rate of healing

efficacy of a fractured bone using plates and screw, are supplied to the fractured bone in

the shape of (a) the degree of bone contact at the fracture interface and (b) stability

offered to the fracture bone either locally at the fracture interface or distally away at the

fracture interface (O’Rourke et al., 2023). Analyzed how to precisely forecast the

likelihood and risk of fracture, in metastatic femurs using a finite element model. The

material models, loading conditions and critical thresholds however vary in these models

(Balasubramani et al., 2023). The orthopedic surgeons are struggling to treat bone

fractures that occur as a result of accidents.

In order to solve this problem, external stabilization of fractured bones is done by the

use of screws and locking compression plates. We modeled the bone of the femur,

locking compression plate, and screws in this study. We proceeded to analyze the

available materials to join plates with other materials (Naidu Manubolu et al. 2022).

Bones are the structural support of the body that supports the body and safeguards the

vital organs as well as providing us with a solid structure to move around. Learning

about bone mechanics is relevant to learn about bone breakage and how and why it

occurs. Fractures occur when the pressure or the weight on a bone surpasses its ability to

support the weight (Kalaiyarasan et al., 2020). Bones are very important tissues

composing calcium and phosphorus. They multiply rapidly during their young years and

mend themselves satisfactorily. The human skeleton is vital as bones give support to the

rest of the body which is usually soft. In case bones break, one of the most common

ways of treating them is through bone joints that rejoin the broken parts (Fouad, 2011).

In order to facilitate the stabilization of the bone structure, a number of internal fixation

instruments such as bone plates are implanted (Innocenti et al., 2016). The femur

skeleton is capable of supporting 25 percent of the body weight of the height of the

person. It is capable of supporting 2500 N (4 times the body weight) without causing a

noticeable reduction in the factor of safety (Ceddia et al., 2024).

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The commercially available bone plates comprised of biocompatible metallic materials

or metal alloys are used in the current fracture fixation technique. To aid in the healing

process, these bone plates are often attached to one side of the fracture. Prosthesis

geometry, material characteristics, and surface finishing are the most crucial aspects of

femoral prosthesis design that impact a prosthetic bioimplant's long-term life.

Furthermore, the dissimilarities between the rigidity of a native bone and a bioimplant

are blamed for the prosthesis's failure. For prostheses to survive over time, the crucial

biomechanical factors at the bone bioimplant interface must be carefully taken into

account. High stiffness is known to lead to problems with stress shielding, which

ultimately leads to the failure of a bioimplant. On the other hand, extremely low

stiffness may result in micro dislocation and prosthesis migration. Prosthetic bone

bioimplants have been designed and developed using conventional metallic biomaterials

like titanium alloy (Ti-6Al-4V) and stainless steel (SS 316L) (Ahirwar et al., 2021).

The most common type of implant fabrication material is the stainless steel (SS316L).

The stainless steel (SS316L) is very rigid with high modulus (approximately 200Gpa)

which makes it very likely to create strong shielding effect (Basirom et al., 2023).

Despite these generalized impressions, the quantitative study in a direct and numerical

manner of the effects of the two materials on the biomechanics of eccentric fracture of

the femur at realistic conditions of multiload carries a strong clinical implication in the

judgment (Zhang et al., 2021a).

Finite Element Method (FEM) is considered to be one of the most broadly embraced

computational tools used to model biomechanical structures. FEM is a numerical

method of solving complicated structural and mechanical problems that are not easy to

solve numerically by other standard analytical methods. In biomechanical studies, solid

modeling packages like SolidWorks have been popular in the creation of three

dimensional models that are very similar to the structures of the human body. These

models are then imported to simulation platforms to be analyzed in detail in the

mechanical analysis.

The interactive method of Finite Element Analysis (FEA) is now a common tool of

biomedical study in systematic exploration of biomechanical behavior. With the help of

software programs like COMSOL Multiphysics, scientists are able to build more

detailed three dimensional models which are able to depict the detailed cortical structure

of bones like the femur. Using FEA, stress and strain distribution can be generated and

visualized in the bone-implant system. Specifically, parameters of von Mises stress on

the plate and bone surfaces could be assessed, which makes them a promising non-

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invasive and reliable means of estimating the implant performance and measuring the

effect of stress shielding in the case of various loading conditions (Ronsivalle et al.,

2025).

The goal of this research is to create a bone plate implant for the femur bone.

COMSOL is used to design the implant to analyze and compare the mechanical

behavior of titanium and stainless steel under identical loading and boundary conditions

using finite element analysis. The study focuses on evaluating stress distribution and

displacement responses to determine the effect of material selection and identify the

more suitable material for load-bearing applications.

2. METHODOLOGY

A comparative biomechanical study of the Femur plate screw system was done using the

Finite element method (FEM) in comsol Multiphysics in a stringent procedure to

guarantee the reliability of the simulation. This was done by creating a 3D model of the

femur, plate and screws with the correct anatomical dimensions and material properties.

The materials were allocated depending on the nature of the bone (cortical and

cancellous bone) and the implantation materials such as titanium or stainless steel.

Previous conditions were used to model real-life constraints, including fixing the femur

on the proximal end and leaving the end of the plate and screws, simulating their real-life

connection. Compressive, shear, and bending forces were simulated to physiologically

load the system in order to reproduce activities that humans typically perform during

walking or standing. The model has been divided into smaller elements using a meshing

strategy so that it can have more mesh density on the areas that are considered to be

critical in calculating stress and strain. The findings helped in the understanding of the

mechanical performance and possible points of failure of the system under different

loading conditions.

2.1Geometrical Model of a Bone Plate

The anatomy model of simulating a bone fracture is made in 3D that is comprised of

two important structures; the outer solid cortical bone and the inner porous cancellous

core. The outer layer of bone, the cortical bone is built to have a radius of 15mm and

height of 200mm. This is a thick, compact layer of bones and serves the purpose of

strength and protection, as does the same in the human body. This shell of the cortex is

the cancellous bone, which is of spongy less dense structure; its radius measures 10mm

and its height 200mm. The cancellous bone or the inner core is what makes the bone

flexible and shock absorbing which aids in the distribution of forces within the bone.

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The cancellous core is enclosed in the solid cortical bone in the model, which is a precise

replica of the natural structure of the long bones, like the femur or the tibia.

To model a fracture, a transversal gap of 1mm is inserted at the mid-shaft which is an

unstable bone fracture. This discontinuity means that the bone cannot carry the loads

directly across the fractured bone. Rather, load-bearing across the fracture site should be

carried all by an implant construct. The fracture is represented and has an elliptical

cross-section along the long axis of the bone so that it is a true model of a fracture that

can happen in practice. The elliptical form of this model helps in the structural integrity

of the model and also makes the model suitable in biomechanical simulations.

The fractured bone is stabilized by the implant which is made of a plate of height

150mm, width 17mm and thickness 3mm which is the normal size of an orthopedic

plate used to fix a fracture. This plate acts as the support as well as glue between the two

parts of the broken bone. Seven screws are applied so that the plate can securely be in

position. These screws have been designed as cylindrical designs with a radius of 3.5mm

and a height of 22mm, which is the average size of screws in orthopedic surgeries. The

screws are fit through pre-formed holes on the plate and it should be ensured to fit in

the cortical bone in the right manner to transfer the actual weight, the screws were

placed within the holes provided in the plate as indicated in Fig:1.

Figure 1: 3D Model of femoral bone with plate and screws

2.2Materials

their

and

characteristics

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The two representative metal biomaterials that could represent the bone plate design

were Ti-6Al-4V and SS 316L. Table 1 summarizes the metallic biomaterials including

their physical and mechanical properties including their density, Young’s modulus,

Poisson ratio and tensile strength. The density of SS 316L is 7870kg/m3 and tensile

strength of 600Mpa is better than Ti-6Al-4V (Ahirwar et al., 2021).

Table 1:Finite element model components used material properties

Young's Modulus

(Pa)

Poisson's

Ratio (v)

Component

Material

Density

Cortical Bone

Plate+Screw

Isotropic Elastic

17e9 Pa

0.3

1900 kg/m3

4430 kg/m3

Titanium (Ti-Al- 1.1e11 Pa

4V)

0.34

Plate+Screw

Stainless steel (SS 193e9 Pa

316 L)

0.3

7870

3

m

2.3FEM Boundary Condition

A load and a boundary condition are applied to the bone plate and solid mechanics

analysis with COMSOL Multiphysics is applied.

2.3.1 Fixed Support

The distal end of the bone of the femur was given a fixed support as presented in the

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Fig:2.

Figure 2: distal end of the femur bone receives fixed support

2.3.2 Load

Figure 3 and 4 depict that a load of -1000 N was applied to the proximal end of the

bone of the femur and a load of 1.1 MPa was applied to the surface of the bone that is

opposite to the plate (Zhang et al., 2021b). This was done again with both plate

Figure 3: -1000N force is applied on the proximal end of femoral bone

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materials to determine the biomechanical response of the system to these loading

conditions.

Figure 4: 1.1MPa pf load pressure is applied on the bone surface opposite to the plate

2.4

Mesh and Study

A sophisticated tetrahedric mesh of fine (0.2-0.5mm) elements in fracture regions and

screws. Convergence affirmed <5% maximum variation in stress (Das & Sarangi, 2014).

This reaction was aroused during the nonlinear geometry and contact stationary study to

provide the correct analysis of stability.

3. RESULTS AND DISCUSSION

To compare the biomechanical performance of both Ti-6Al-4V (Titanium Alloy) and

SS316L (Stainless Steel) bone plate systems, both alloys were tested in the same

conditions of application and loading boundaries. Boundary loads which were 1000 N

and proximal end of the femur and the pressure on the opposite surface of the plate

which was 1.1 MPa was identical in both material systems. The greatest distinction

between the two materials is the mechanical properties especially the stiffness, strength,

and elasticity. Consequently, the behavior of the plate in deformation of the femur

system was different based on the material in which the plate was made. Ti-6Al-4V is a

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titanium alloy that is known to be lightweight and its strength to weight ratio is much

higher and therefore, tends to deform relatively less to the applied loads. Conversely,

SS316L, austenitic stainless steel, is more rigid and flexible than titanium which means

that it deforms differently in the same loading conditions. Such material behavior

differences are observed in the deformation trajectories as the degree and distribution of

stress and strain throughout the system are different in the two materials, which provide

an insight into the behavior and the appropriateness of each material to the orthopedic

uses.

3.1Force is Applied on the Proximal End of Femoral Bone

For Ti-6Al-4V material, the displacement is between 0 to 4.867mm. and the max von

Mises stress is 6.088E8 N/m² as shown in Fig:5. The 2D displacement contour on

Figure 5: 3D displacement and von Mises stress in Ti-6Al-4V material

Fig:6 affirmed the displacement was greatest about the fracture gap than about the other

parts of the bone. The point graph in 1D illustrates in fig. 7 the relationship between

stress and displacement, showing how stress decreases as displacement increases. This

graph is crucial for understanding the behavior of the material under different loading

conditions.

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For Stainless steel (SS 316L) material, the displacement is between 0 to 4.546 mm. and

the max von Mises stress is 6.485E8 N/m² as shown in Fig:8. The 2D contour of the

displacement as depicted in Fig:9 confirmed the fact that the deformation was highest

around the fracture gap than the rest of the bone. The point graph in 1D illustrates in

fig:10 the relationship between stress and displacement, showing how stress decreases as

displacement increases. This graph is crucial for understanding the behavior of the

material under different loading conditions.

Figure 7: 1D point graph of Ti material

Figure 9: 2D displacement contour in SS

Figure 7: 1D point graph of Ti material

Figure 6: 2D displacement contour in Ti

Figure 8: 3D displacement and von Mises stress in SS 316L material

3.2

Pressure is Applied on the Bone Surface Opposite to the Plate

For Titanium alloy (Ti-6Al-4V) material, the displacement is between 0 to 9.283 mm.

and the max von Mises stress is 3.019E9 N/m² as shown in Fig:11. The 2D contour of

the displacement as shown in Fig:12 was useful in supporting how the greatest

deformation was on the bone around the fracture gap than in other areas. The point

graph in 1D illustrates in Fig:7 the relationship between stress and displacement,

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showing how stress decreases as displacement increases. This graph is crucial for

understanding the behavior of the material under different loading conditions.

Figure 11: 3D displacement and von Mises stress in Ti-6Al-4V material

Figure 12: 2D displacement contour in Ti

For

Stainless

(SS 316L)

material,

steel

the

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displacement is between 0 to 8.970 mm. and the max von Mises stress is 3.617E9

N/m² as shown in Fig:13. The 2D contour of the displacement as shown in Fig:14 was

useful in supporting how the greatest deformation was on the bone around the fracture

gap than in other areas. The point graph in 1D illustrates in fig:10 the relationship

between stress and displacement, showing how stress decreases as displacement increases.

This graph is crucial for understanding the behavior of the material under different

loading conditions.

Figure 13: 3D displacement and von Mises stress in SS 316L material

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Figure 14: 2D displacement contour in SS

4. CONCLUSION & FUTURE WORK

The comparative analysis of the mechanical performance of two orthopedic materials

that are commonly used in orthopedic implantation, including Titanium alloy (Ti-6Al-4

V) and Stainless Steel (SS316L), was made possible through the finite element analysis

conducted in this study. The findings also showed that Ti-6Al-4V is more rigid and

structurally stable during the physiological loading conditions. This could be seen in the

lower values of deformation and displacement values recorded on the titanium alloy

model than on SS316L. Reduced displacement also implies that the implant has a

higher ability to maintain its structural integrity and withstand the bending or

mechanical distortion when exposed to the external loads, which is critical in the

assurance of stability of fixation constructs in fractured bones.

Conversely, SS316L demonstrated a higher displacement which implies that it is more

flexible and less rigid when subjected to the same loading. Although a degree of

deformation might be useful in some biomedical applications, too much deformation

can adversely affect the ability of implants to stay in place, especially when the implant is

required to support a load as with orthopedic implant items like bone plates and screws.

High displacement may cause micro-movements at the fracture site that might influence

fracture healing and extend the adverse consequences of fatigue or mechanical failure

over time of implants. Thus, according to the findings obtained during the finite

element analysis, Ti-6Al-4V could be regarded as a better choice of material to be used

in orthopedic implantation with high mechanical stability and long-lasting performance,

i.e., the fracture fixation plate and screw (Dudko, 2025).

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The future step in work should be to perform tests on such materials under more

complicated, dynamic loading conditions that can replicate real-life movements and

investigate how surface treatments or coating can enhance biocompatibility and wear and

corrosion resistance, as well as use patient-specific considerations to make the test more

personalized. More so, the finite element models should be experimentally approved by

in vitro and in vivo experiments to validate the results and optimize the design and

materials selection of implants, in order to achieve improved clinical results.

5. REFERENCES

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