skip to main content


Title: Correlation-function-based microstructure design of alloy-polymer composites for dynamic dry adhesion tuning in soft gripping

Tunable dry adhesion is a crucial mechanism in compliant manipulation. The gripping force can be controlled by reversibly varying the physical properties (e.g., stiffness) of the composite via external stimuli. The maximal gripping force Fmaxand its tunability depend on, among other factors, the stress distribution on the gripping interface and its fracture dynamics (during detaching), which in turn are determined by the composite microstructure. Here, we present a computational framework for the modeling and design of a class of binary smart composites containing a porous low-melting-point alloy (LMPA) phase and a polymer phase, in order to achieve desirable dynamically tunable dry adhesion. We employ spatial correlation functions to quantify, model, and represent the complex bi-continuous microstructure of the composites, from which a wide spectrum of realistic virtual 3D composite microstructures can be generated using stochastic optimization. A recently developed volume-compensated lattice-particle method is then employed to model the dynamic interfacial fracture process, where the gripper is detached from the object, to compute Fmaxfor different composite microstructures. We focus on the interface defect tuning mechanism for dry adhesion tuning enabled by the composite, and find that for an optimal microstructure among the ones studied here, a tenfold dynamic tuning of Fmaxbefore and after the thermal expansion of the LMPA phase can be achieved. Our computational results can provide valuable guidance for experimental fabrication of the LMPA–polymer composites.

 
more » « less
Award ID(s):
2020277
NSF-PAR ID:
10363882
Author(s) / Creator(s):
 ;  ;  ;  ;  ;  ;  
Publisher / Repository:
American Institute of Physics
Date Published:
Journal Name:
Journal of Applied Physics
Volume:
131
Issue:
11
ISSN:
0021-8979
Page Range / eLocation ID:
Article No. 115104
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. Abstract

    Tunable dry adhesion has a range of applications, including transfer printing, climbing robots, and gripping in automated manufacturing processes. Here, a novel concept to achieve dynamically tunable dry adhesion via modulation of the stiffness of subsurface mechanical elements is introduced and demonstrated. A composite post structure, consisting of an elastomer shell and a core with a stiffness that can be tuned via application of electrical voltage, is fabricated. In the nonactivated state, the core is stiff and the effective adhesion strength between the composite post and contact surface is high. Activation of the core via application of electrical voltage reduces the stiffness of the core, resulting in a change in the stress distribution and driving force for delamination at the interface and, thus a reduction in the effective adhesion strength. The adhesion of composite posts with a range of dimensions is characterized and activation of the core is shown to reduce the adhesion by as much as a factor of 6. The experimentally observed reduction in adhesion is primarily due to the change in stiffness of the core. However, the activation of the core also results in heating of the interface and this plays a secondary role in the adhesion change.

     
    more » « less
  2. Abstract

    In this study, we discuss the characterization and quantification of composite microstructures formed by the external field manipulation of high aspect ratio magnetic particles in an elastomeric matrix. In our prior work, we have demonstrated that the simultaneous application of electric and magnetic fields on hard magnetic particles with geometric anisotropy can create a hierarchy of structures at different length scales, which can be used to achieve a wide range of properties. We aim to characterize these hierarchical structures and relate them to final composite properties so we can achieve our ultimate goal of designing a material for a prescribed performance. The complex particle structures are formed during processing by using electric and magnetic fields, and they are then locked-in by curing the polymer matrix around the particles. The model materials used in the study are barium hexaferrite (BHF) particles and polydimethylsiloxane (PDMS) elastomer. BHF was selected for its hard magnetic properties and high geometric anisotropy. PDMS was selected for its good mechanical properties and its tunable curing kinetics. The resulting BHF-PDMS composites are magnetoactive, i.e., they will deform and actuate in response to magnetic fields. In order to investigate the resulting particle orientation, distribution and alignment and to predict the composite’s macro scale properties, we developed techniques to quantify the particle structures.

    The general framework we developed allows us to quantify and directly compare the microstructures created within the composites. To identify structures at the different length scales, images of the composite are taken using both optical microscopy and scanning electron microscopy. We then use ImageJ to analyze them and gather data on particle size, location, and orientation angle. The data is then exported to MATLAB, and is used to run a Minimum Spanning Tree Algorithm to classify the particle structures, and von Mises Distributions to quantify the alignment of said structures.

    Important findings show 1) the ability to control structure using a combination of external electric, magnetic and thermal fields; 2) that electric fields promote long range order while magnetic fields promote short-range order; and 3) the resulting hierarchical structure greatly influence bulk material properties. Manipulating particles in a composite material is technologically important because changes in microstructure can alter the properties of the bulk material. The multifield processing we investigate here can form the basis for next generation additive manufacturing platforms where desired properties are tailored locally through in-situ hierarchical control of particle arrangements.

     
    more » « less
  3. Abstract

    Recently, a novel concept to realize dynamically tunable dry adhesion via subsurface stiffness modulation (SSM) in a composite core–shell structure has been introduced and demonstrated for gripping and release of objects. Here, a variant form of the composite core–shell design is proposed to significantly improve the performance of dynamically tunable dry adhesion in terms of activation time and activation voltage. Specifically, composite pillars with an embedded microfluidic channel filled with a low melting point alloy (LMPA) are fabricated, and the adhesion of the pillars is characterized as a function of LMPA state: either melted or solid. The effects of the thickness and in‐plane pattern of the LMPA channel, as well as the depth at which it is embedded on tunable adhesion are investigated. Experiments show that the effective adhesion strength can be reduced up to 50%, equivalent to a 2× change in dry adhesion when the LMPA is melted. Finite element analysis of the stress distribution change under SSM shows that the experimentally observed tunable adhesion is primarily due to stiffness change close to the interface. In addition, two technology demonstrations of composite pillars picking and releasing objects with fast activation (≈1 s) and low activation voltages (≈1 V) are included.

     
    more » « less
  4. In this study, we investigated hierarchical microarchitecture formation of magnetic barium hexaferrite (BF) platelets inside the polydimethylsiloxane (PDMS) matrix using electric and magnetic field colloidal assembly technique. First, external fields were applied to the colloidal solution to form the microstructure before curing the composites. After microstructure formation the composites were cured to freeze the microstructure by the application of heat. We investigated two different cases in this study-(1) magnetic field processed composites and (2) multi-field processed composites which were processed under both magnetic and electric field. We observed that macro-chains formed due to the electric and magnetic field had much higher length compared to the macro-chains formed due to the just magnetic field. For both cases individuals BHF are found to be oriented in the direction of external field. The analysis of SEM microstructures using ImageJ and MATLAB showed that at least two different level of hierarchies are present in the microstructure for both cases which can be named as BHF stacks and micro-chains. From the microstructure analysis, we found that compared to just magnetic field processed composites, the orientation of individual particles, BHF stacks and micro-chains in relation to the external field were found to be higher for the multi-field processed composites. Magneto-electro-hydrodynamics modeling of the polymer-particulate mixture predicted similar behavior. Computational simulations were performed wherein particulates, subjected to both DEP forces and additional magnetic dipole interactions, were allowed to form quasi-equilibrium structures before locking in a final structure to represent curing. Results show that dielectrophoretic (DEP) force produced from the local non-uniform electric field facilitates the translation of the platelets towards formation of chain-like structure, while external magnetic field augmented the rotation of particles inside the chain-like structure. Analysis of the simulation of microstructures confirms that multiple level of hierarchies are present in the composites microstructure for both cases, while the case with both electric and magnetic fields produced longer chains. The understanding of the hierarchical microstructure formation using the multi-field processing technique will help in the future to fabricate more complex microarchitectures with resulting multi-material properties. 
    more » « less
  5. In this manuscript, we present a multiscale Adaptive Reduced-Order Modeling (AROM) framework to efficiently simulate the response of heterogeneous composite microstructures under interfacial and volumetric damage. This framework builds on the eigendeformation-based reduced-order homogenization model (EHM), which is based on the transformation field analysis (TFA) and operates in the context of computational homogenization with a focus on model order reduction of the microscale problem. EHM pre-computes certain microstructure information by solving a series of linear elastic problems defined over the fully resolved microstructure (i.e., concentration tensors, interaction tensors) and approximates the microscale problem using a much smaller basis spanned over subdomains (also called parts) of the microstructure. Using this reduced basis, and prescribed spatial variation of inelastic response fields over the parts, the microscale problem leads to a set of algebraic equations with part-wise responses as unknowns, instead of node-wise displacements as in finite element analysis. The volumetric and interfacial influence functions are calculated by using the Interface enriched Generalized Finite Element Method (IGFEM) to compute the coefficient tensors, in which the finite element discretization does not need to conform to the material interfaces. AROM takes advantage of pre-computed coefficient tensors associated with the finest ROM and efficiently computes the coefficient tensors of a series of gradually coarsening ROMs. During the multiscale analysis stage, the simulation starts with a coarse ROM which can capture the initial elastic response well. As the loading continues and response in certain parts of the microstructure starts to localize, the analysis adaptively switches to the next level of refined ROM to better capture those local responses. The performance of AROM is evaluated by comparing the results with regular EHM (no adaptive refinement) and IGFEM under different loading conditions and failure modes for various 2D and 3D microstructures. The proposed AROM provides an efficient way to model history-dependent nonlinear responses for composite materials under localized interface failure and phase damage. 
    more » « less