Design of Circular Cross-Section Corner-Filleted Flexure Hinges for Three-Dimensional Compliant Mechanisms

The paper introduces the circular cross-section corner-filleted flexure hinges as connectors in three-dimensional compliant mechanism applications. Compliance factors are derived analytically for bending, axial loading and torsion. A circular cross-section corner-filleted flexure hinge belongs to a domain delimited by the cylinder (no fillet) and the right circular cross-section flexure hinge (maximum fillet radius). The analytical model predictions are confirmed by finite element simulation and experimental measurements. The circular cross-section corner-filleted flexure hinges are characterized in terms of their compliance, precision of rotation and stress levels.