Research Papers

Design Optimization Challenges of Origami-Based Mechanisms With Sequenced Folding

[+] Author and Article Information
Kazuko Fuchi

Wright State Research Institute,
4035 Colonel Glenn Highway,
Suite 200,
Beavercreek, OH 45431
e-mail: kazuko.fuchi@wright.edu

Philip R. Buskohl

Material and Manufacturing Directorate,
Air Force Research Laboratory,
Wright-Patterson AFB, OH 45433
e-mail: philip.buskohl.1@us.af.mil

Giorgio Bazzan

UES, Inc.,
4401 Dayton Xenia Road,
Beavercreek, OH 45432
e-mail: giorgio.bazzan.1.ctr@us.af.mil

Michael F. Durstock

Material and Manufacturing Directorate,
Air Force Research Laboratory,
Wright-Patterson AFB, OH 45433
e-mail: michael.durstock@us.af.mil

Gregory W. Reich

Aerospace Systems Directorate,
Air Force Research Laboratory,
2210 Eighth Street,
WPAFB, OH 45433
e-mail: gregory.reich.1@us.af.mil

Richard A. Vaia

Material and Manufacturing Directorate,
Air Force Research Laboratory,
Wright-Patterson AFB, OH 45433
e-mail: richard.vaia@us.af.mil

James J. Joo

Aerospace Systems Directorate,
Air Force Research Laboratory,
2210 Eighth Street,
Wright-Patterson AFB, OH 45433
e-mail: james.joo.1@us.af.mil

1Corresponding author.

Manuscript received September 14, 2015; final manuscript received December 11, 2015; published online May 4, 2016. Assoc. Editor: Andrew P. Murray. Adopted from conference paper DETC2015-47420.The United States Government retains, and by accepting the article for publication, the publisher acknowledges that the United States Government retains, a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for United States government purposes.

J. Mechanisms Robotics 8(5), 051011 (May 04, 2016) (6 pages) Paper No: JMR-15-1261; doi: 10.1115/1.4032442 History: Received September 14, 2015

Reconfigurable structures based on origami design are useful for multifunctional applications, such as deployable shelters, solar array packaging, and tunable antennas. Origami provides a framework to decompose a complex 2D to 3D transformation into a series of folding operations about predetermined foldlines. Recent optimization toolsets have begun to enable a systematic search of the design space to optimize not only geometry but also mechanical performance criteria as well. However, selecting optimal fold patterns for large folding operations is challenging as geometric nonlinearity influences fold choice throughout the evolution. The present work investigates strategies for design optimization to incorporate the current and future configurations of the structure in the performance evaluation. An optimization method, combined with finite-element analysis, is used to distribute mechanical properties within an initially flat structure to determine optimal crease patterns to achieve desired motions. Out-of-plane and twist displacement objectives are used in three examples. The influence of load increment and geometric nonlinearity on the choice of crease patterns is studied, and appropriate optimization strategies are discussed.

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Grahic Jump Location
Fig. 3

Twist crease pattern undetectable with single step analysis of a flat reference state: (a) schematic of problem boundary conditions and design objective, (b) optimal solution obtained using one, two, and ten load steps, (c) deformed configurations of optimal designs, and (d) prototypes fabricated via laser machining polypropylene

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Fig. 5

Response surface plot of the objective as a function of load step and fold stiffness, α*, of the highlighted foldlines. Fold stiffness of the additional chomper lines determines the performance outcome.

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Fig. 4

Chomper variations: (a) action origami [18], (b) simplified chomper design and its flat-foldable variation, and (c) chomper design problem specifications

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Fig. 2

Flow chart of the design optimization proces. The load step of the structure is incremented by updating the load magnitude, system matrices, and the displacement field (i=1, 2, …N). The topology optimization algorithm uses the objective function and constraints at i=n to compute the design update.

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Fig. 6

Square twist design: (a) design problem specifications, (b) optimal solution obtained using linear analysis, and (c) series of folding path images showing sequence of vertical displacement followed by twist motion

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Fig. 7

Potential optimization strategies include: optimizing for both fold stiffness and fold termination point (parametrized through displacement); concentrating the computational effort in the critical region, where the transition of different phases of folding motion occurs

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Fig. 1

Origami analysis using modified truss elements: (a) a flat “sheet” discretized using modified truss elements and (b) fold stiffness distribution and responses of foldlines under loading



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