Simulation and Topology Optimization of a Vehicle Door Hinge for Additive Manufacturing

Abstract

Additive manufacturing technologies offer unique capabilities that result in the creation of innovative, high-performance complex design geometries at reduced material cost. These novel design approaches can be fully realized through topology optimization which allows for greater material distribution usually optimized against a specific design objective. A vehicle door hinge design was analyzed using a finite element analysis which was then optimized to be additively manufactured with AlSi10Mg alloy. Based on the results of the structural analysis, topology optimization was performed to remove material from areas that did not significantly contribute to carrying the required loads. From the topology optimization results, the part was then remodeled in CAD software for additive manufacture using the AlSi10Mg alloy. Additional finite element analyses were carried out on the new CAD model to determine the load-carrying capacity of the design. The final design was then prepared for the final additive manufacturing. Keywords—additive manufacturing, aluminum alloy, compliance, finite element analysis, topology optimization