Integrated Design and Fabrication of Pneumatic Soft Robot Actuators in a Single Casting Step.

Bio-inspired soft robots have already shown the ability to handle uncertainty and adapt to unstructured environments. However, their availability is partially restricted by time-consuming, costly, and highly supervised design-fabrication processes, often based on resource-intensive iterative workflows. Here, we propose an integrated approach targeting the design and fabrication of pneumatic soft actuators in a single casting step. Molds and sacrificial water-soluble hollow cores are printed using fused filament fabrication. A heated water circuit accelerates the dissolution of the core's material and guarantees its complete removal from the actuator walls, while the actuator's mechanical operability is defined through finite element analysis. This enables the fabrication of actuators with non-uniform cross-sections under minimal supervision, thereby reducing the number of iterations necessary during the design and fabrication processes. Three actuators capable of bending and linear motion were designed, fabricated, integrated, and demonstrated as 3 different bio-inspired soft robots, an earthworm-inspired robot, a 4-legged robot, and a robotic gripper. We demonstrate the availability, versatility, and effectiveness of the proposed methods, contributing to accelerating the design and fabrication of soft robots. This study represents a step toward increasing the accessibility of soft robots to people at a lower cost.

Effect of Residual Stresses on Fatigue Crack Growth: A Numerical Study Based on Cumulative Plastic Strain at the Crack Tip.

Residual stresses affect the fatigue behavior, given that compressive stresses delay the phenomenon, while tensile stresses accelerate it. However, the mechanisms behind the effect of residual stresses are not totally understood. A numerical study is developed here to understand the effect of thermal residual stresses (TRSs) on fatigue crack growth (FCG). The crack driving force was assumed to be the cumulative plastic strain at the crack tip. The heating of a region ahead of the crack tip produced elastic compressive TRS, which were 69% of material's yield stress. Alternatively, plastic deformation was produced by severe cooling followed by heating to generate compressive residual stresses. The crack propagation in the compressive residual stress field produced a decrease in the FCG rate. On the other hand, without the contact of crack flanks, the TRS showed no effect on FCG. Therefore, the TRSs only affect FCG by changing the crack closure level.

Analysis of ESAFORM 2021 cup drawing benchmark of an Al alloy, critical factors for accuracy and efficiency of FE simulations.

This article details the ESAFORM Benchmark 2021. The deep drawing cup of a 1 mm thick, AA 6016-T4 sheet with a strong cube texture was simulated by 11 teams relying on phenomenological or crystal plasticity approaches, using commercial or self-developed Finite Element (FE) codes, with solid, continuum or classical shell elements and different contact models. The material characterization (tensile tests, biaxial tensile tests, monotonic and reverse shear tests, EBSD measurements) and the cup forming steps were performed with care (redundancy of measurements). The Benchmark organizers identified some constitutive laws but each team could perform its own identification. The methodology to reach material data is systematically described as well as the final data set. The ability of the constitutive law and of the FE model to predict Lankford and yield stress in different directions is verified. Then, the simulation results such as the earing (number and average height and amplitude), the punch force evolution and thickness in the cup wall are evaluated and analysed. The CPU time, the manpower for each step as well as the required tests versus the final prediction accuracy of more than 20 FE simulations are commented. The article aims to guide students and engineers in their choice of a constitutive law (yield locus, hardening law or plasticity approach) and data set used in the identification, without neglecting the other FE features, such as software, explicit or implicit strategy, element type and contact model.

FCG Modelling Considering the Combined Effects of Cyclic Plastic Deformation and Growth of Micro-Voids.

Fatigue is one of the most prevalent mechanisms of failure. Thus, the evaluation of the fatigue crack growth process is fundamental in engineering applications subjected to cyclic loads. The fatigue crack growth rate is usually accessed through the da/dN-ΔK curves, which have some well-known limitations. In this study a numerical model that uses the cyclic plastic strain at the crack tip to predict da/dN was coupled with the Gurson-Tvergaard-Needleman (GTN) damage model. The crack propagation process occurs, by node release, when the cumulative plastic strain reaches a critical value. The GTN model is used to account for the material degradation due to the growth of micro-voids process, which affects fatigue crack growth. Predictions with GTN are compared with the ones obtained without this ductile fracture model. Crack closure was studied in order to justify the lower values of da/dN obtained in the model with GTN, when compared with the results without GTN, for lower ΔK values. Finally, the accuracy of both variants of the numerical model is accessed through the comparison with experimental results.

Revisiting Classical Issues of Fatigue Crack Growth Using a Non-Linear Approach.

Fatigue crack growth (FCG) has been studied for decades; however, several aspects are still objects of controversy. The objective here is to discuss different issues, using a numerical approach based on crack tip plastic strain, assuming that FCG is driven by crack tip deformation. ΔK was found to control cyclic plastic deformation at the crack tip, while Kmax has no effect. Therefore, alternative mechanisms are required to justify models based on ΔK and Kmax. The analysis of crack tip plastic deformation also showed that there is crack tip damage below crack closure. Therefore, the definition of an effective load range ΔKeff = Kmax - Kopen is not correct, because the portion of load range below opening also contributes to FCG. Below crack closure, damage occurs during unloading while during loading the crack tip deformation is elastic. However, if the maximum load is decreased below the elastic limit, which corresponds to the transition between elastic and elasto-plastic regimes, there is no crack tip damage. Additionally, a significant effect of the crack ligament on crack closure was found in tests with different crack lengths and the same ΔK. Finally, the analysis of FCG after an overload with and without contact of crack flanks showed that the typical variation of da/dN observed is linked to crack closure variations, while the residual stresses ahead of crack tip are not affected by the contact of crack flanks.