An improved design method for the dimensional synthesis of flexure-based compliant mechanisms: optimization procedure and experimental validation. Berselli, G, Meng, Q, Vertechy, R, & Castelli, V P 2015.
An improved design method for the dimensional synthesis of flexure-based compliant mechanisms: optimization procedure and experimental validation [link]Paper  doi  abstract   bibtex   
Monolithic Flexure-based Compliant Mechanisms (MFCM) can be used to conceive nonlinear springs with a desired load-displacement profile at one point of their structure. For a given MFCM topology, these particular springs can be conveniently dimensioned by resorting to the well-known Pseudo-Rigid-Body approximation, whose accuracy strongly depends on the modelling precision of the flexures' principal compliance. For various types of flexures, closed-form solutions have been proposed, which express the compliance factors as functions of the flexure dimensions. Nonetheless, the accuracy of these relations is limited to slender, beam-like hinges undergoing rather small deflections. In order to overcome such limitations, this paper provides empirical equations, derived from finite element analysis, that can be used for the optimal dimensioning of circular, elliptical, and corner-filleted flexural hinges with general aspect ratios, on the basis of both principal compliance and maximum bearable stress. At first, an accuracy comparison with previously published results is provided. Then, as a case study, a nonlinear spring based on a double slider-crank MFCM and with a desired load-displacement profile is dimensioned and verified via finite element analysis. The corresponding MFCM prototype, produced by means of water jet cutting, is finally tested on a tensile stage. Both numerical and experimental results confirm that the aforementioned empirical equations outperform the closed-form solutions provided in the past literature when modelling thick cross-section hinges undergoing significant deflections. \textcopyright 2015 Springer Science+Business Media Dordrecht
@misc{Berselli2015,
abstract = {Monolithic Flexure-based Compliant Mechanisms (MFCM) can be used to conceive nonlinear springs with a desired load-displacement profile at one point of their structure. For a given MFCM topology, these particular springs can be conveniently dimensioned by resorting to the well-known Pseudo-Rigid-Body approximation, whose accuracy strongly depends on the modelling precision of the flexures' principal compliance. For various types of flexures, closed-form solutions have been proposed, which express the compliance factors as functions of the flexure dimensions. Nonetheless, the accuracy of these relations is limited to slender, beam-like hinges undergoing rather small deflections. In order to overcome such limitations, this paper provides empirical equations, derived from finite element analysis, that can be used for the optimal dimensioning of circular, elliptical, and corner-filleted flexural hinges with general aspect ratios, on the basis of both principal compliance and maximum bearable stress. At first, an accuracy comparison with previously published results is provided. Then, as a case study, a nonlinear spring based on a double slider-crank MFCM and with a desired load-displacement profile is dimensioned and verified via finite element analysis. The corresponding MFCM prototype, produced by means of water jet cutting, is finally tested on a tensile stage. Both numerical and experimental results confirm that the aforementioned empirical equations outperform the closed-form solutions provided in the past literature when modelling thick cross-section hinges undergoing significant deflections. {\textcopyright} 2015 Springer Science+Business Media Dordrecht},
address = {Universit{\`{a}} di Genova, Via allOpera Pia 15/A, Genova, Italy},
annote = {Export Date: 27 March 2016

Article in Press

CODEN: MECCB

Correspondence Address: Vertechy, R.; Universit{\`{a}} di Bologna, Viale Risorgimento 2, Italy},
author = {Berselli, G and Meng, Q and Vertechy, R and Castelli, V P},
booktitle = {Meccanica},
doi = {10.1007/s11012-015-0276-z},
file = {:E$\backslash$:/6{\_}PUBBLICAZIONI/iris{\_}pdf{\_}files/pdf{\_}post{\_}print/an improved method for spring design.pdf:pdf},
isbn = {00256455 (ISSN) },
keywords = {Accuracy comparisons,Aspect ratio,Closed form solutions,Compliant mechanisms,Design,Design method,Design methods,Dimensional synthesis,Experimental validations,Fighter aircraft,Finite element analysis,Finite element method,Flexural hinges,Hinges,Mechanisms,Optimization procedures,Pseudo-rigid body models,Pseudo-rigid-body model,Rigid structures},
language = {English},
publisher = {Kluwer Academic Publishers},
title = {{An improved design method for the dimensional synthesis of flexure-based compliant mechanisms: optimization procedure and experimental validation}},
url = {http://www.scopus.com/inward/record.url?eid=2-s2.0-84941710593{\&}partnerID=40{\&}md5=37d76d745995aa2aa36e6d26b04ed2bd},
year = {2015}
}

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