Building Block Synthesis of Self-Supported Three-Dimensional Compliant Elements for Metallic Additive Manufacturing

可制造性设计 顺应机制 机制(生物学) 机械工程 块(置换群论) 制作 铰链 实现(概率) 3D打印 双稳态 结构工程 计算机科学 材料科学 工程类 几何学 有限元法 物理 医学 统计 量子力学 病理 替代医学 光电子学 数学
作者
Aschraf N. Danun,Philip D. Palma,Christoph Klahn,Mirko Meboldt
出处
期刊:Journal of Mechanical Design [American Society of Mechanical Engineers]
卷期号:143 (5) 被引量:14
标识
DOI:10.1115/1.4048220
摘要

Abstract Compliant mechanisms gain motion through the elastic deformation of the monolithic flexible elements. The geometric design freedom of metallic additive manufacturing enables the fabrication of complex and three-dimensional (3D) compliant elements within mechanisms previously too complicated to produce. However, the design of metallic additive manufactured mechanisms faces various challenges of manufacturing restrictions, such as avoiding critical overhanging geometries and minimizing the amount of support structure, which has been reported in a few cases. This paper presents a synthesis approach for translational compliant elements, involving building blocks based on leaf-type springs and covering building orientations between 0 deg and 90 deg. In particular, this range is approached by the synthesis of self-supported 3D building blocks with orientations of 0 deg, 45 deg and 90 deg. The compliant elements are built based on linear and circular plane curves and compared numerically according to their mechanical performance to create preferable building blocks. The applicability of the presented procedure and the manufacturability of the compliant mechanisms are proven by printing individual 3D building blocks and their serial aggregation with laser-based powder bed fusion. Consequently, several prototypes are demonstrated, including a bistable switch mechanism and a large displaceable rotational spring joint. In addition, a small-scale highly maneuverable segment of a surgical instrument with a grasping mechanism at the distal end is proposed.
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