On material selection for topology optimized compliant mechanisms

Abstract Although compliant mechanism design is a thoroughly studied field, surprisingly little information can be found in literature regarding selection of optimal materials. This paper is intended to fill this gap. Density-based, geometrically robust, stress constrained topology optimization based on a total Lagrangian FEM formulation is used for investigation of a compliant inverter and a compliant gripper example. Changes in handling of the projection parameters and the stress constraints are proposed for improved algorithmic stability and accurate representation of the stresses and material stiffness in topology optimization. Large-scale optimization studies are carried out, varying elastic modulus and allowable stress in a wide range. A comparison with an Ashby chart shows the characteristics of the best suited material. It is shown, that an optimal Young’s modulus and a minimum required material strength (depending on the modulus) can be identified from the results. Altering critical optimization parameters, e.g. allowable volume fraction and the minimum length scale, their influence on the optimal material choice is investigated. Guidelines for compliant mechanism designers for efficient selection of suited materials are developed.

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