Browse Publications Technical Papers 2020-01-0599
2020-04-14

A Robust Methodology for Predicting the Fatigue Life of an Automotive Closures System Subjected to Hinge and Check Link Load 2020-01-0599

Quality in the automotive industry symbolizes the development and the manufacturing of vehicles whose specifications meet customer requirements. Among the quality issues, opening and closing effort of any closures in a vehicle is a characteristic that strongly affects the customer first opinion about vehicle design. The closure opening and closing effort is affected by different uncertainties like opening angle, load to the check-link, hinge stoppage, materials and manufacturing process. A check stop & hinge stop load durability cycle occurs when a customer opens the closures beyond the closure detent position with a force applied on the check link or hinge check stops. Due to few uncertainties like abuse opening, manufacturing imperfections, weak mounting locations, the closures will be subjected to fatigue failure. The present study is aimed to introduce a probabilistic frame-work for fatigue life reliability analysis that addresses the uncertainties associated with door opening-closing effort due to check-hinge loads, door closure opening angles and hinge stop tolerance. A fatigue life probabilistic model of various closure systems was developed using Monte-Carlo simulation, where the stress range intercept and slope of the fatigue life curve from afore mentioned variable parameters were consider as random variable. Weibull or log normal distribution is most efficient for fatigue life estimates. This present simulation is used to define door opening effort variability due to variation of the hinge and check link position. This analysis allows defining maximum allowable hinge and check link position variability in order to keep door opening effort below a target value. Simulated distribution is compared to experimentally door effort analysis showing very good agreement between them. Furthermore, a reliability based design optimization is carried out using Equivalent Model Technique to position the exact mounting location of check link between the hinges for automotive doors.

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