Nonlinear Dynamics and Wear Characteristics of a High-Frequency Flapping-Wing Mechanism with Multiple Revolute-Joint Clearances

High-frequency flapping-wing mechanisms have attracted increasing interest in micro aerial vehicles and low-altitude intelligent systems because of their strong hovering performance, high maneuverability, and adaptability to complex environments. However, most existing dynamic studies assume ideal kinematic joints and rigid components, limiting their ability to capture the coupled effects of revolute-joint clearances, structural flexibility, and wear. In this study, a rigid–flexible coupled dynamic model is developed for a high-frequency flapping-wing mechanism considering revolute-joint clearances and wear evolution. Contact–impact and frictional effects at the clearance joints are incorporated, while the flexible wing components are modeled using the absolute nodal coordinate formulation (ANCF). An Archard-based wear model is further introduced to describe clearance-induced degradation. The effects of component flexibility, clearance size, number of clearance joints, and flapping frequency on the dynamic response and wear behavior of the mechanism are systematically investigated. The results show that larger clearances, a greater number of clearance joints, and higher flapping frequencies intensify response fluctuations and increase the peak acceleration, driving torque, and contact–impact force. Structural flexibility further modifies the contact behavior through elastic deformation and energy transfer, thereby amplifying impact responses during certain phases of motion. The proposed framework provides a theoretical basis for dynamic performance assessment, wear prediction, and reliability-oriented design of high-precision biomimetic flapping-wing mechanisms.