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Description
The trend in vibrator module design for vibration-assisted machining involves utilizing flexural hinges as vibrational transmitters from the actuator to the cutting tool. Polynomial flexural hinges represent a type that provides greater flexibility to designers, as polynomial hinges can encompass properties of other hinge types. This study aims to demonstrate the influence of polynomial hinge design parameters through finite element analysis. These simulations were used to analyze the effects of polynomial hinge design parameters (i.e., polynomial orders, hinge thickness, and hinge length) on deflection at the tooltip and hinge stress. A full factorial design with five levels for each parameter was implemented. Increasing polynomial orders and longer hinges increased deflection by twofold (0.9–2.04 µm), and hinge stress by similar order of magnitude (61–112 MPa). Within the combinations studied, grey relation analysis indicated the optimal conditions for a combination polynomial hinge designs with a polynomial order n of 2, a thickness of 4 mm, and a length of 6 mm. This combination resulted in a tool deflection of 1.47 μm and stress of 39.1 MPa. Consequently, this study is expected to contribute to the knowledge about polynomial hinge design for the vibration-assisted machining, enabling its application across various industries.
