Fatigue life prediction in a door hinge system under uni-axial and multi-axial loading conditions

This thesis presents the use of Finite Element (FE) based fatigue analysis to locate the critical point of crack initiation and predict life in a door hinge system that is subjected to both uni-axial and multi-axial loading. The results are experimentally validated. The FE model is further used to obtain an optimum design per the standard requirement in the ground vehicle industry. The accuracy of the results showed that FE based fatigue analysis can be successfully employed to reduce costly and time-consuming experiments in the preliminary design stage. Numerical analysis also provides the product design engineers with substantial savings, enabling the testing of fewer prototypes.

Fatigue life prediction in a door hinge system under uni-axial and multi-axial loading conditions

This thesis presents the use of Finite Element (FE) based fatigue analysis to locate the critical point of crack initiation and predict life in a door hinge system that is subjected to both uni-axial and multi-axial loading. The results are experimentally validated. The FE model is further used to obtain an optimum design per the standard requirement in the ground vehicle industry. The accuracy of the results showed that FE based fatigue analysis can be successfully employed to reduce costly and time-consuming experiments in the preliminary design stage. Numerical analysis also provides the product design engineers with substantial savings, enabling the testing of fewer prototypes.

The mine blast algorithm for the structural optimization of electrical vehicle components

The shape optimization of mechanical and automotive component plays a crucial role in the development of automotive technology. Presently, the use of derivative-free metaheuristics in combination with finite element analysis for mechanical component design is one of the most focused on topics due to its simplicity and effectiveness. In this research paper, the mine blast algorithm (MBA) is used to solve the problem of shape optimization for a vehicle door hinge to prove how the MBA can be used for solving shape optimization problems in designing electrical vehicles. The results show the advantage of the MBA for designing optimal components in the automotive industry.

On the Problem of Optimizing the Door Hinge of Electro Car by Generative Design Methods

Our research describes the optimization of car door hinges. The model we are considering is a pair of upper and lower hinges of car doors and cases of their loading. Optimization of this part of the vehicle consists in reducing the mass of the product, which is taken as the target function, while maintaining the mechanical characteristics within acceptable values. The characteristics of various types of manufacturing, such as milling, casting, and additive manufacturing, were also used as optimization criteria. During the research the authors have undertaken the task of using the most advanced approaches for calculation, optimization and analysis of their results, which are the use of special calculation systems, calculations that are performed on the GPU, what is the way much reduces the required optimization time, methods of generative design to achieve the required criteria and consideration of possible methods of manufacture of the workpiece in terms of additive manufacturing. The result of our research is the concept of optimizing vehicle door hinges and selecting the appropriate production method. As a test of the positive effect of the applied method, a repeated static calculation of the structure was made, based on the optimized geometry.