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1. Pseudo-Rigid Body Dynamic Modeling of Compliant Members for Design

   https://doi.org/10.1115/DETC2019-97881  

   Vedant; Allison, James T. (August 2019, American Society of Mechanical Engineers)

   Movement in compliant mechanisms is achieved, at least in part, via deformable flexible members, rather than using articulating joints. These flexible members are traditionally modeled using Finite Element Models (FEMs). In this article, an alternative strategy for modeling compliant cantilever beams is developed with the objectives of reducing computational expense, and providing accuracy with respect to design optimization solutions. The method involves approximating the response of a flexible beam with an n-link/m-joint Pseudo-Rigid Body Dynamic Model (PRBDM). Traditionally, PRBDM models have shown an approximation of compliant elements using 2 or 3 revolute joints (2R/3R-PRBDM). In this study, a more general nR-PRBDM model is developed. The first n resonant frequencies of the PRBDM are matched to exact or FEM solutions to approximate the response of the compliant system. These models can be used for co-design studies of flexible structural members, and are capable of modeling higher deflection of compliant elements. 

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2. Machine Learning Based Deflection Prediction and Inverse Design for Discrete Variable Stiffness Units

   https://doi.org/10.1115/DETC2023-117322  

   Fu, Jiaming; Guo, Qianyu; Gan, Dongming (August 2023, American Society of Mechanical Engineers)

   Abstract Large deflection modeling is a crucial field of study in the analysis and design of compliant mechanisms (CM). This paper proposes a machine learning (ML) approach for predicting the deflection of discrete variable stiffness units (DSUs) that cover a range from small to large deflections. The primary structure of a DSU consists of a parallel guide beam with a hollow cavity that can change stiffness discretely by inserting or extracting a solid block. The principle is based on changing the cross-sectional area properties of the hollow section. Prior to model training, a large volume of data was collected using finite element analysis (FEA) under different loads and various dimensional parameters. Additionally, we present three widely used machine learning-based models for predicting beam deflection, taking into account prediction accuracy and speed. Several experiments are conducted to evaluate the performance of the ML models that were compared with the FEA and analytical model results. The optimal ML model, multilayer perceptron (MLP), can achieve a 7.9% maximum error compared to FEA. Furthermore, the model was employed in a practical application for inverse design, with various cases presented depending on the number of solved variables. This method provides a innovative perspective for studying the modeling of compliant mechanisms and may be extended to other mechanical mechanisms. 

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3. A Novel Variable Stiffness Compliant Robotic Link Based on Discrete Variable Stiffness Units for Safe Human-Robot Interaction

   https://doi.org/10.1115/DETC2022-89825  

   Fu, Jiaming; Lin, Han; Xu, Wei; Gan, Dongming (August 2022, ASME International Design Engineering Technical Conferences and Computers and Information in Engineering Conference)

   Abstract Variable stiffness manipulators balance the trade-off between manipulation performance needing high stiffness and safe human-robot interaction desiring low stiffness. Variable stiffness compliant links provide a solution to enable this flexible manipulation function in human-robot co-working scenarios. In this paper, we propose a novel variable stiffness link based on discrete variable stiffness units (DSUs). A DSU is a parallel guided beam that can adjust stiffness discretely by changing the cross-sectional area properties of the hollow beam segments. The variable stiffness link (named Tri-DSU) consists of three tandem DSUs to achieve eight stiffness modes and a maximum stiffness change ratio of 31. To optimize the design, stiffness analysis of the DSU and Tri-DSU under various configurations and forces was performed by a derived theoretical model compared with finite element analysis (FEA). The analytical stiffness model is derived using the approach of serially connected beams and superposition combinations. It works not only for thin-walled flexure beams but also for general thick beam models. 3-D printed prototypes were built to verify the feature and performance of the Tri-DSU in comparison with the FEA and analytical model results. It’s demonstrated that our analytical model can accurately predict the stiffnesses of the DSU and Tri-DSU within a certain range of parameters. The developed variable stiffness link method and analytical model are extendable to multiple DSUs with different sizes and parameter configurations to achieve modularization and customization. The advantages of the stiffness change mechanism are rapid actuation, simple structure, and compact layout. These methods and results provide a new conceptual and theoretical basis for the development of new reconfigurable cobot manipulators, variable stiffness structures, and compliant mechanisms. 

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4. Using cohesive zone models with digital image correlation to obtain a mixed mode I/II fracture envelope of a tough epoxy

   https://doi.org/10.1016/j.engfracmech.2023.109732  

   Jackson, Christopher M; McGuire, Jeffrey A; Losada, Martin E; Maskery, Ian; Ashcroft, Ian; De_Vita, Raffaella; Dillard, David A (January 2024, Engineering Fracture Mechanics)

   This work describes a method in which the digital image correlation (DIC) method and finite element analysis (FEA) were used to create a quasi-static mixed-mode fracture envelope for bonded joints consisting of 2024-T3 Al adherends and a tough structural epoxy adhesive. Symmetric and asymmetric versions of double cantilever beam, single-leg bend, and end-notched flexure tests are used to populate the mixed-mode fracture envelope with results at several mode mixities. Experiments are conducted in a universal testing machine while recording images for subsequent DIC analysis. Finite element analysis is used to implement cohesive zone models (CZMs) of the adhesive fracture and to account for plastic deformation of adherends. Mode I and mode II traction separation laws (TSLs) are determined from a property identification method with a Benzeggagh–Kenane mixed-mode coupling law used to model mixed-mode behavior. FEA results are shown to provide a good agreement to both the crosshead displacement and DIC data. The methods in this paper serve as a potential framework for future calibration of mixed-mode fracture envelopes for joints bonded with very tough adhesives that complicate assessment with traditional data analysis methods. 

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5. Experimental Analysis of Shell-like Deployable Anchors for Increased Tensile Resistance

   https://doi.org/10.20898/j.iass.2024.011  

   Tucker, Kaylee A; Sychterz, Ann C (December 2024, Journal of the International Association for Shell and Spatial Structures)

   Structures with deployable and compliant mechanisms are new to the domain of underground geotechnical systems. An anchor with rotationally deploying compliant thin-wall elements has been developed. This paper presents variations of this anchor that are targeted to increase the surface area associated with the anchor. This increased surface area correlates to higher skin friction to better resist tensile forces. The number and sizing of the deployable components, called awns, are investigated. The work presented here includes methods to change the deployment behavior of the awns by changing the shape of the awns and by using functionally graded materials for increased resistance when the anchor is subjected to uplift forces. Test members were fabricated from a combination of flexible and rigid polymers via additive manufacturing. Experimental testing included anchor deployment tests and awn tension tests. For deployment tests, torque was applied to an anchor placed in clear sand. Awn tension tests provided additional information about the deformation of functionally graded awns through isolated testing of the awns. The presented design and experimental methodologies give insights into the behavior of small-scale deployable anchors. 

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