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Topologies of large deformation Contact-aided Compliant Mechanisms (CCMs),with self and mutual contact, exemplified via path generation applications, aredesigned using the continuum synthesis approach. Design domains areparameterized using honeycomb tessellation. Assignment of material to eachcell, and generation of rigid contact surfaces, are accomplished via suitablysizing and positioning negative circular masks. To facilitate contact analysis,boundary smoothing is implemented. Mean value coordinates are employed tocompute shape functions, as many regular hexagonal cells get degenerated intoirregular, concave polygons as a consequence of boundary smoothing. Both,geometric and material nonlinearities are considered in the finite elementanalysis. The augmented Lagrange multiplier method in association with anactive set strategy is employed to incorporate both self and mutual contact.CCMs are evolved using the stochastic hill climber search. Synthesizedcontact-aided compliant continua trace paths with single and importantly,multiple kinks and experience multiple contact interactions pertaining to bothself and mutual contact modes.

Computational synthesis of large deformation compliant mechanisms undergoing self and mutual contact