Design and analysis of a contact-aided flexure hinge (CAFH) with variable stiffness

This paper presents a novel contact-aided flexure hinge (CAFH) with variable stiffness, which consists of a contact-aided segment, a flexible segment and a rigid part. The proposed CAFH can facilitate a compact design and provide an alternative for stiffness-variable designs under any loading conditions. With a mortise-tenon structure, the CAFH is trivially affected by friction. The design and deformation procedures of the CAFH are described in detail, followed by its theoretical kinetostatic modeling using the chained beam-constraint model. The deformation of all segments is considered in the kinetostatic model, which expands the space of design parameters for stiffness-variable designs. Then, the accuracy of the theoretical model and the variable stiffness design are verified by nonlinear finite element analysis (FEA) and experimental tests. In term of stiffness, the maximum relative errors of the theoretical model are 0.76% in Stage 1 and 0.70% in Stage 2, as compared with FEA, respectively. Further, the parameter sweep is carried out, followed by sensitivity analysis to identify the main test error sources. Finally, the multi-material scenarios are investigated preliminarily, and some outlooks are discussed.