An innovative design method for compliant mechanisms combining structural optimisations and designer creativity

This paper proposes an innovative, integrated design method for the design of practical and sophisticated compliant mechanisms. The approach consists of two optimisation methods, topology and shape optimisation, plus a scheme to implement designer input of ideas. In the first step, a designer explores the most fruitful design concepts for mechanisms that achieve the design specifications, by combining compliant mechanisms created by the topology optimisation with additional mechanisms prepared by the designer. In this first step, a support method based on the visualisation of the designer's thinking processes assists the designer in his or her exploration of new ideas and design concepts. In the second step, the shape optimisation yields a detailed optimal shape based on the design concept. The combination of compliant mechanisms with the additional mechanisms enables the creation of devices having increased capability or higher performance than would be possible using a single compliant mechanism designed by topology optimisation alone. Executing the shape optimisation after initial design concepts have been explored facilitates the determination of a detailed optimal shape, and also enables to consider non-linear analysis and stress concentration and to make accurate quantitative performance evaluations, which topology optimisation cannot provide.

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