Digital optimization of car’s hinged components

Abstract

Abstract The purpose of this work is to reduce the weight of the car’s hinged structures (front and rear doors, tailgate and lock reinforcements) by using various types of optimization which involve removing material, changing thicknesses, and topography from parts (topology, topography, parameter and multivariate) as well as the interpretation of optimization results for specific types of production while maintaining the rigidity and strength characteristics. This technique is necessary to reduce the time for product development and reduce the cost of manufacturing parts. This study addressed the issue of the maximum possible weight reduction while meeting all the requirements (strength calculations, stiffness calculations, modal analysis, analysis of resistance to external loads, local rigidity of the door attachment points - strength loadcases, stiffness loadcases, modal, denting, IPI) and technological limitations (Envelope requirements, casting technology). The final design solution was required to contain visible changes from the original structure, meet performance requirements, and obtain a feasibility study from the production department.