The topology optimization problem for the synthesis of compliant mechanisms has been formulated in many different ways in the past 15years, 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 parametrizations, 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, and the ability to converge from an unbiased uniform initial guess are analyzed. Some observations and recommendations 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.
A linkage of rigid bodies under gravity loads can be statically counter-balanced by adding compensating gravity loads. Similarly, gravity loads or spring loads can be counter-balanced by adding springs. In the current literature, among the techniques that add springs, some achieve perfect static balance while others achieve only approximate balance. Further, all of them add auxiliary bodies to the linkage in addition to springs. We present a perfect static balancing technique that adds only springs but not auxiliary bodies, in contrast to the existing techniques. This technique can counter-balance both gravity loads and spring loads. The technique requires that every joint that connects two bodies in the linkage be either a revolute joint or a spherical joint. Apart from this, the linkage can have any number of bodies connected in any manner. In order to achieve perfect balance, this technique requires that all the spring loads have the feature of zero-free-length, as is the case with the existing techniques. This requirement is neither impractical nor restrictive since the feature can be practically incorporated into any normal spring either by modifying the spring or by adding another spring in parallel.
There are analytical methods in the literature where a zero-free-length spring-loaded linkage is perfectly statically balanced by addition of more zero-free-length springs. This paper provides a general framework to extend these methods to flexure-based compliant mechanisms through (i) the well know small-length flexure model and (ii) approximation between torsional springs and zero-free-length springs. We use first-order truncated Taylor's series for the approximation between the torsional springs and zero-free-length springs so that the entire framework remains analytical, albeit approximate. Three examples are presented and the effectiveness of the framework is studied by means of finite-element analysis and a prototype. As much as 70% reduction in actuation effort is demonstrated. We also present another application of static balancing of a rigid-body linkage by treating a compliant mechanism as the spring load to a rigid-body linkage.
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