Optimal Design and Experimental Validation of Compliant Mechanical Amplifiers for Piezoceramic Stack Actuators

An optimization method has been developed for design of compliant mechanical amplifiers for piezoceramic stack actuators. A topology optimization approach is used where the objective is to maximize the stroke amplification, and results show good algorithm convergence and good mechanism performance. The focus of this paper is on using the optimal topology solution to generate a solid model, and on improving the actuator performance through detail design and analysis of the resulting monolithic compliant mechanical amplifiers. A study of the effect of various flexure hinge configurations and other design parameters on the amplification and mechanical advantage of an actuator is performed. Another actuator with a large stroke amplification is designed using a batch of random starting points to the optimization algorithm. Prototype actuators have been fabricated, and the results of experimental validations are presented.