Four kinds of feet with typical structures, referred to as the hemispherical foot, the semicylindrical foot, the rectangular foot and the circular foot, respectively, were designed and manufactured to study the foot–terrain interaction mechanics for legged robots. Three kinds of quartz sand were selected to study how particle size, shape and compactness affected the physical properties of the substrate and the intrusion performance of mechanical feet. The media with smaller particle sizes had higher bulk densities and lower angles of stability, but no obvious rule was found for particle shapes of quartz sand with different sizes. The intrusion resistive forces and pressures of the hemispherical foot on these three kinds of quartz sand were all less compared with the other three mechanical feet. The particle disturbance areas and motion trends were compared under these four kinds of mechanical feet using discrete element method simulations. The intrusion resistive forces of these mechanical feet first increased and then decreased with the increasing particle sizes of the quartz sand. Moreover, the intrusion resistive forces of these mechanical feet on spherical particles were smaller compared with irregular particles. The corresponding resistive forces of the mechanical feet were characterized based on the compactness of the quartz sand. According to the intrusion test data, the classic pressure–sinkage model was modified, and the relationships between intrusion resistive force and mechanical foot depth were obtained.
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