Research on topology optimization of compliant mechanisms is extensive but the design of flexure hinges using topology optimization method is comparatively rare. This paper deals with topology optimization of flexure hinges undergoing large-displacement. The basic optimization model is developed for topology optimization of the revolute hinge. The objective function for the synthesis of large-displacement flexure hinges are proposed together with constraints function. The geometrically nonlinear behaviour of flexure hinge is modelled using the total Lagrangian finite element formulation. The equilibrium is found by using a Newton-Raphson iterative scheme. The sensitivity analysis of the objective functions are calculated by the adjoint method and the optimization problem is solved using the method of moving asymptotes (MMA). Numerical examples are used to show the validity of the proposed method and the differences between the results obtained by linear and nonlinear modelling are large.

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