Optimum design of two-material bending plate compliant devices

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Augusto Romero
Keyword(s):  
Topology Optimization ◽  
Optimum Design ◽  
Compliant Mechanisms ◽  
Base Material ◽  
Planar Mechanisms ◽  
Qualitative Comparison ◽  
Content Type ◽  
Topological Derivatives ◽  
Plate Models ◽  
Representation Method

PurposeThe purpose of this study is to explore the optimum design of bending plate compliant mechanisms subjected to pure mechanical excitations using topological-derivative-based topology optimization. The main objective is to design the reinforcement in a plate of base material.Design/methodology/approachThe optimum design is performed by means of a level-set representation method guided by topological derivatives. Kirchhoff and Reissner–Mindlin models are used to solve the linear bending plate problem. A qualitative comparison has been carried out between the optimal obtained topologies for each model.FindingsThe proposed methodology was able to design reinforcement in a plate of the base material. The obtained reinforcements notably improve the device’s behavior. The shape and topology of the reinforcements vary depending on the mechanical plate model considered. In fact, in the Reissner–Mindlin solutions, very thin flexo-torsional hinges connecting big zones of the reinforcement material are designed.Originality/valueUp to date, the synthesis of ortho-planar mechanisms by means of continuum topology optimization was only boarded within a multi-physics context. In this work, the optimal design of pure ortho-planar compliance actuators is addressed. The best performance is found by analyzing the results for two classical mechanical plate models.

Experimental verification of robust topology optimization for compliant mechanism

2020 ◽  
Vol 26 (9) ◽  
pp. 1485-1502
Author(s):  
Xiaojun Wang ◽  
Zhenxian Luo ◽  
Xinyu Geng
Keyword(s):  
Experimental Data ◽  
Topology Optimization ◽  
3D Printing ◽  
Robust Optimization ◽  
Compliant Mechanisms ◽  
Compliant Mechanism ◽  
Deterministic Optimization ◽  
Content Type ◽  
Robust Topology Optimization ◽  
Test Pieces

Purpose This paper is to present an experiment to verify that the motion errors of robust topology optimization results of compliant mechanisms are insensitive to load dispersion. Design/methodology/approach First, the test pieces of deterministic optimization and robust optimization results are manufactured by the combination of three-dimensional (3D) printing and casting techniques. To measure the displacement of the test piece of compliant mechanism, a displacement measurement method based on the image recognition technique is proposed in this paper. Findings According to the experimental data analysis, the robust topology optimization results of compliant mechanisms are less sensitive to uncertainties, comparing with the deterministic optimization results. Originality/value An experiment is presented to verify the effectiveness of robust topology optimization for compliant mechanisms. The test pieces of deterministic optimization and robust optimization results are manufactured by the combination of 3D printing and casting techniques. By comparing the experimental data, it is found that the motion errors of robust topology optimization results of compliant mechanisms are insensitive to load dispersion.

Environmental tests of embedded thin- and thick-film resistors in comparison to chip resistors

Circuit World ◽  
2014 ◽  
Vol 40 (1) ◽  
pp. 7-12 ◽  
Author(s):  
Wojciech Steplewski ◽  
Andrzej Dziedzic ◽  
Janusz Borecki ◽  
Grazyna Koziol ◽  
Tomasz Serzysko
Keyword(s):  
Thin Film ◽  
Thick Film ◽  
Electrical Resistance ◽  
Printed Circuit Boards ◽  
Base Material ◽  
Forming Process ◽  
Content Type ◽  
Thin Film Resistors ◽  
Embedded Resistors ◽  
The Impact

Purpose – The purpose of this paper is to investigate the influence of parameters of embedded resistive elements manufacturing process as well as the influence of environmental factors on their electrical resistance. The investigations were made in comparison to the similar constructions of discrete chip resistors assembled to standard printed circuit boards (PCBs). Design/methodology/approach – The investigations were based on the thin-film resistors made of NiP alloy, thick-film resistors made of carbon or carbon-silver inks as well as chip resistors in 0402 and 0603 packages. The polymer thick-film resistive films were screen-printed on the several types finishing materials of contact terminations such as copper, silver, and gold. To determine the sensitivity of embedded resistors versus standard assembled chip resistors on environmental exposure, the climatic chamber was used. The measurements of resistance were carried out periodically during the tests, and after the exposure cycles. Findings – The results show that the change of electrical resistance of embedded resistors, in dependence of construction and base material, is different and mainly not exceed the range of 3 per cent. The achieved results in reference to thin-film resistors are comparable with results for standard chip resistors. However, the results that were obtained for thick-film resistors with Ag and Ni/Au contacts are similar. It was not found the big differences between resistors with and without conformal coating. Research limitations/implications – The studies show that embedded resistors can be used interchangeably with chip resistors. It allows to save the area on the surface of PCB, occupied by these passive elements, for assembly of active elements (ICs) and thus enable to miniaturization of electronic devices. But embedding of passive elements into PCB requires to tackle the effect of each forming process steps on the operational properties. Originality/value – The technique of passive elements embedding into PCB is generally known; however, there are no detailed reports on the impact of individual process steps and environmental conditions on the stability of their electrical resistance. The studies allow to understand the importance of each factor process and the mechanisms of operational properties changes depending on the used materials.

Piezoelectric Actuator Performance Metrics and Relation to Compliant Mechanism Design

2001 ◽  
Author(s):  
Hima Maddisetty ◽  
Mary Frecker
Keyword(s):  
Topology Optimization ◽  
Performance Metrics ◽  
Compliant Mechanisms ◽  
Compliant Mechanism ◽  
Mechanical Efficiency ◽  
High Energy ◽  
High Energy Density ◽  
High Bandwidth ◽  
Compliant Mechanism Design ◽  
Actuator Performance

Abstract Piezoceramic actuators have gained widespread use due to their desirable qualities of high force, high bandwidth, and high energy density. Compliant mechanisms can be designed for maximum stroke amplification of piezoceramic actuators using topology optimization. In this paper, the mechanical efficiency and other performance metrics of such compliant mechanism/actuator systems are studied. Various definitions of efficiency and other performance metrics of actuators with amplification mechanisms from the literature are reviewed. These metrics are then applied to two compliant mechanism example problems and the effect of the stiffness of the external load is investigated.

Optimization design of titanium alloy connecting rod based on structural topology optimization

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bin Zheng ◽  
Yi Cai ◽  
Kelun Tang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Optimization Design ◽  
Equivalent Stress ◽  
Connecting Rod ◽  
Element Analysis ◽  
Content Type ◽  
The Finite Element Analysis ◽  
Maximum Equivalent Stress

Purpose The purpose of this paper is to realize the lightweight of connecting rod and meet the requirements of low energy consumption and vibration. Based on the structural design of the original connecting rod, the finite element analysis was conducted to reduce the weight and increase the natural frequencies, so as to reduce materials consumption and improve the energy efficiency of internal combustion engine. Design/methodology/approach The finite element analysis, structural optimization design and topology optimization of the connecting rod are applied. Efficient hybrid method is deployed: static and modal analysis; and structure re-design of the connecting rod based on topology optimization. Findings After the optimization of the connecting rod, the weight is reduced from 1.7907 to 1.4875 kg, with a reduction of 16.93%. The maximum equivalent stress of the optimized connecting rod is 183.97 MPa and that of the original structure is 217.18 MPa, with the reduction of 15.62%. The first, second and third natural frequencies of the optimized connecting rod are increased by 8.89%, 8.85% and 11.09%, respectively. Through the finite element analysis and based on the lightweight, the maximum equivalent stress is reduced and the low-order natural frequency is increased. Originality/value This paper presents an optimization method on the connecting rod structure. Based on the statics and modal analysis of the connecting rod and combined with the topology optimization, the size of the connecting rod is improved, and the static and dynamic characteristics of the optimized connecting rod are improved.

scholarly journals Multiscale, thermomechanical topology optimization of self-supporting cellular structures for porous injection molds

2019 ◽  
Vol 25 (9) ◽  
pp. 1482-1492
Author(s):  
Tong Wu ◽  
Andres Tovar
Keyword(s):  
Topology Optimization ◽  
Mechanical Performance ◽  
Mechanical Load ◽  
Design Method ◽  
Three Dimensional ◽  
Optimization Method ◽  
Cellular Structures ◽  
Injection Mold ◽  
Computationally Efficient ◽  
Content Type

Purpose This paper aims to establish a multiscale topology optimization method for the optimal design of non-periodic, self-supporting cellular structures subjected to thermo-mechanical loads. The result is a hierarchically complex design that is thermally efficient, mechanically stable and suitable for additive manufacturing (AM). Design/methodology/approach The proposed method seeks to maximize thermo-mechanical performance at the macroscale in a conceptual design while obtaining maximum shear modulus for each unit cell at the mesoscale. Then, the macroscale performance is re-estimated, and the mesoscale design is updated until the macroscale performance is satisfied. Findings A two-dimensional Messerschmitt Bolkow Bolhm (MBB) beam withstanding thermo-mechanical load is presented to illustrate the proposed design method. Furthermore, the method is implemented to optimize a three-dimensional injection mold, which is successfully prototyped using 420 stainless steel infiltrated with bronze. Originality/value By developing a computationally efficient and manufacturing friendly inverse homogenization approach, the novel multiscale design could generate porous molds which can save up to 30 per cent material compared to their solid counterpart without decreasing thermo-mechanical performance. Practical implications This study is a useful tool for the designer in molding industries to reduce the cost of the injection mold and take full advantage of AM.

Topology Optimization of Compliant Mechanisms Using Hybrid Discretization Model

2010 ◽  
Vol 132 (11) ◽  
Author(s):  
Hong Zhou
Keyword(s):  
Topology Optimization ◽  
Compliant Mechanisms ◽  
Compliant Mechanism ◽  
Optimization Procedure ◽  
Optimization Method ◽  
Diagonal Element ◽  
Initial Guess ◽  
Stress Constraint ◽  
Design Variables ◽  
Hybrid Discretization

The hybrid discretization model for topology optimization of compliant mechanisms is introduced in this paper. The design domain is discretized into quadrilateral design cells. Each design cell is further subdivided into triangular analysis cells. This hybrid discretization model allows any two contiguous design cells to be connected by four triangular analysis cells whether they are in the horizontal, vertical, or diagonal direction. Topological anomalies such as checkerboard patterns, diagonal element chains, and de facto hinges are completely eliminated. In the proposed topology optimization method, design variables are all binary, and every analysis cell is either solid or void to prevent the gray cell problem that is usually caused by intermediate material states. Stress constraint is directly imposed on each analysis cell to make the synthesized compliant mechanism safe. Genetic algorithm is used to search the optimum and to avoid the need to choose the initial guess solution and conduct sensitivity analysis. The obtained topology solutions have no point connection, unsmooth boundary, and zigzag member. No post-processing is needed for topology uncertainty caused by point connection or a gray cell. The introduced hybrid discretization model and the proposed topology optimization procedure are illustrated by two classical synthesis examples of compliant mechanisms.

A Comparative Study of the Formulations for Topology Optimization of Compliant Mechanisms

2008 ◽  
Author(s):  
Sangamesh R. Deepak ◽  
M. Dinesh ◽  
Deepak Sahu ◽  
Salil Jalan ◽  
G. K. Ananthasuresh
Keyword(s):  
Topology Optimization ◽  
Comparative Study ◽  
Compliant Mechanisms ◽  
Computation Time ◽  
Initial Guess ◽  
Benchmark Problems ◽  
Topology Optimization Problem ◽  
Linear Elastic ◽  
Frame Element ◽  
Force Direction

The topology optimization problem for the synthesis of compliant mechanisms has been formulated in many different ways in the last 15 years, but there is not yet a definitive formulation that is universally accepted. Furthermore, there are two unresolved issues in this problem. In this paper, we present a comparative study of five distinctly different formulations that are reported in the literature. Three benchmark examples are solved with these formulations using the same input and output specifications and the same numerical optimization algorithm. A total of 35 different synthesis examples are implemented. The examples are limited to desired instantaneous output direction for prescribed input force direction. Hence, this study is limited to linear elastic modeling with small deformations. Two design parameterizations, namely, the frame element based ground structure and the density approach using continuum elements, are used. The obtained designs are evaluated with all other objective functions and are compared with each other. The checkerboard patterns, point flexures, the ability to converge from an unbiased uniform initial guess, and the computation time are analyzed. Some observations are noted based on the extensive implementation done in this study. Complete details of the benchmark problems and the results are included. The computer codes related to this study are made available on the internet for ready access.

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