In the topology optimization of compliant mechanisms,positional and shape factors signifi-cantly affect structural mechanical properties.The formation of concentrated hinge regions not only weak-ens structural strength but also hinders manufacturability.To this end,we propose a topology optimiza-tion method for hinge-free compliant mechanisms,incorporating geometric nonlinearity and utilizing the bi-directional evolutionary structural optimization(BESO)method.Initially,the design domain is dis-cretized,where the 0-1 distribution of the BESO method prevents element distortion during nonlinear finite element analysis,thus enhancing numerical stability and convergence.The deformations of the compliant mechanism at the input and output are constrained under unit excitation,effectively suppressing the emer-gence of concentrated hinges.This leads to improved structural strength and manufacturability.Finally,hinge-free mechanisms are fabricated via additive manufacturing.Experimental results from samples show excellent agreement with finite element simulations,validating the effectiveness of the proposed hinge-sup-pression strategy in compliant mechanism design.
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