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Rigid-body mechanisms (RBMs) and compliant mechanisms (CMs) are traditionally treated in significantly different ways. In this paper, we present a synthesis approach that is appropriate for both RBMs and CMs. In this approach, RBMs and CMs are generalized into modularized mechanisms that consist of five basic modules, including compliant links (CLs), rigid links (RLs), pin joints (PJs), compliant joints (CJs), and rigid joints (RJs). The link modules and joint modules are modeled through beam elements and hinge elements, respectively, in a geometrically nonlinear finite-element solver, and subsequently a beam-hinge ground structure model is proposed. Based on this new model, a link and joint determination approach—module optimization—is developed for the type and dimensional synthesis of both RBMs and CMs. In the module optimization approach, the states (both presence or absence and sizes) of joints and links are all design variables, and one may obtain an RBM, a partially CM, or a fully CM for a given mechanical task. Three design examples of path generators are used to demonstrate the effectiveness of the proposed approach to the type and dimensional synthesis of RBMs and CMs.

This paper proposes a topology optimization framework to design compliant mechanisms with a mixed mesh of both beams and flexure hinges for the design domain. Further, a new type of finite element, i.e., super flexure hinge element, was developed to model flexure hinges. Then, an investigation into the effects of the location and size of a flexure hinge in a compliant lever explains why the point-flexure problem often occurs in the resulting design via topology optimization. Two design examples were presented to verify the proposed technique. The effects of link widths and hinge radii were also investigated. The results demonstrated that the proposed meshing scheme and topology optimization technique facilitate the rational decision on the locations and sizes of beams and flexure hinges in compliant mechanisms.

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