The design of a manipulator arm, which is built from a construction kit, is presented in this article. The procedure is based on the results of the discrete optimization of a truss structure and its application to a simple component system (assuming a predefined shape and material of components). A genetic algorithm is used to optimize the truss structure, and the results of the solution are verified on a simple task used in literature (the code was written in the Python language). The construction kit was inspired by Merkur^®, and the article proposes several components with different shapes and materials. The construction kit and the optimization of the truss structure were used to design the manipulator arm. The truss topology has been predefined with respect to the construction set. The finite element method (software ANSYS^®) was used to analyze the components (shell elements) and truss structures (linear analysis, buckling analysis, etc.). To validate the presented approach, the arm designed by topological optimization was used. The comparison shows that the use of components may be an alternative to topology optimization and additive manufacturing. The next step will be the modification of the presented method in order to minimize the differences between the simplified task used for optimization (truss structure-rod element) and the simulation composed of components (components assembly-shell element).

The conventional method for evaluation of the fatigue constants uses one set of experimental data from strain-controlled uniaxial fatigue tests. However, these constants do not ensure the compatibility conditions. The new 3D method retains the mathematical and physical relationships between curves considered. This paper presents a way of implementation of the identification procedure and shows results obtained for three types of materials.

This paper details the possibility of simulating HELICOIL^® inserts using Finite Element Analysis and contact technology. The main procedure is based on the use of contact elements in the Glue–Cohesive setting, which is usually considered for the simulation of composites. The contact represents the behaviour of an interface, including the HELICOIL^® insert, the sample threads, and the screw threads. The behaviour of the cohesive contact is determined by a multi-linear curve, and is described by several parameters. Our main goal is to determine the number of parameters and their values to provide a defined accuracy. The sample is made of ABS-M30 material, while the screw is made of steel. The Finite Element Model Updating method is used to determine the parameters from experimental data. The problem regarding the addition of a point (parameter) to a multi-linear curve is solved using the principle of halving intervals. A gradient approach combined with a penalisation method is used to identify the parameters of the interface model. The simulation results are compared with data obtained through Digital Image Correlation measurements.