Hybrid Compliant Mechanism Design Using a Mixed Mesh of Flexure Hinge Elements and Beam Elements Through Topology Optimization

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.