Size and topology optimization of die casting hinge considering fatigue life

Abstract

Product development cycles are shorter than in the past through the development of CAD and CAE technologies. However, it still takes much time to find the optimal structure when we need to improve or modify the initially designed structure. Moreover, structural stability, such as fatigue life, should be the primary quality information in the optimization process. However, it is estimated not by an accurate fatigue analysis, but by conservative factors of safety or empirical coefficient for various types of conditions. All of this causes a waste of time and cost in a modern design environment that demands optimal performance at reasonable specifications.

In this study, the die casting hinge, which is the door supporting structure of home appliances, is used as an objective part. This study shows the practical design optimization steps based on the size and topology optimization considering fatigue life analysis. Most of the process is performed using the commercial CAE software, ANSYS workbench.|CAD 및 CAE 기술발전에 따라 제품개발 주기 또한 현저히 짧아지고 있다.

그러나 제품의 다양성이 확대 됨에 따라 설계변경 상황들이 수 없이 발생하게 되고, 그 때마다 최적의 구조를 찾고 검증하는 과정에서 여전히 많은 시행착오들이 발생한다. 한편 신뢰성 확보를 위한 시뮬레이션 검증 단계에서도 보수적인 또는 경험적인 안전율을 근거로 설계함에 따라 최적화 효율성이 감소하게 된다. 결국 과잉설계에 따른 비용 낭비, 최적화 오류에 의한 물리적인 시간소모 등으로 개발단계에서 큰 걸림돌이 되기도 한다. 본 연구에서는 가전제품 도어 지지 구조물인 다이캐스팅 힌지를 연구

대상으로 하였으며, 피로수명 해석을 기반으로 사이즈 최적화 및 가공 방향성을 고려한 위상 최적화를 순차적으로 진행함으로써 효과적이고 실용적인 설계개선 및 설계변경 방법을 검증하고자 한다.; Product development cycles are shorter than in the past through the development of CAD and CAE technologies. However, it still takes much time to find the optimal structure when we need to improve or modify the initially designed structure. Moreover, structural stability, such as fatigue life, should be the primary quality information in the optimization process. However, it is estimated not by an accurate fatigue analysis, but by conservative factors of safety or empirical coefficient for various types of conditions. All of this causes a waste of time and cost in a modern design environment that demands optimal performance at reasonable specifications.

In this study, the die casting hinge, which is the door supporting structure of home appliances, is used as an objective part. This study shows the practical design optimization steps based on the size and topology optimization considering fatigue life analysis. Most of the process is performed using the commercial CAE software, ANSYS workbench.