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.