Buckling-induced instability in topology optimization of compliant constant-force mechanisms

Abstract

Compliant constant-force mechanisms are compliant mechanisms that provide a nearly constant force over a prescribed deflection range. Topology optimization is an effective method for compliant constant-force mechanism design. However, instabilities caused by buckling often cause the optimization algorithm to fail to converge. This study analyzes the causes of buckling-induced instability and proposes methods to avoid this instability. A mechanism with three torsional springs is proposed, and its three force–displacement curves are analyzed. These bifurcated force–displacement curves cause the optimization algorithm to be unstable. Several topology optimization models with buckling constraints are proposed for designing compliant constant-force mechanisms. Their effects are tested and analyzed in numerical examples with different target constant forces and constant-force strokes. Almost all optimization results have three hinges, corresponding to a proposed mechanism with three torsion springs. A slight change in their initial design causes a large change in the force–displacement curve, which eventually leads to buckling-induced instability. This instability can be avoided by constraining the buckling load calculated at the configuration near the start of the constant-force stroke.