Door Hinge Design

Simulation of Assem2
Date: 29 2014 .
Designer: ALIKHAN SHAMBUL
Study name: 190N
Analysis type: Static
Table of Contents
Description ............................................ 1
Assumptions .......................................... 2
Model Information ................................... 2
Study Properties ..................................... 4
Units ................................................... 4
Material Properties .................................. 5
Description
This report represents the final project for Computer Aided
Engineering class. The main aim of the project was to design
the regular door hinge that will be able to hold the door.
The parameters material selection dimensions and sizing of
parts were based on conducted research and general
standards used worldwide.
Loads and Fixtures................................... 6

Connector Definitions ............................... 7
Contact Information ................................. 7
Mesh Information .................................... 8
Sensor Details ...................................... 10
Resultant Forces ................................... 10
Beams ................................................ 10
Study Results ....................................... 11
Conclusion .......................................... 16
Analyzed with SolidWorks Simulation
ALIKHAN SHAMBUL
29.11.2014
Assumptions
The very first assumption that was made at the beginning of the project was that the door is being held by
only one hinge that is located at the upper part of the door. Because of that the technique of remote load
that is located at the center of gravity of the door is applied. Furthermore, due to issues regarding
simulation of the assembly that consisted of three parts at the beginning (2 plates and 1 hinge) the hinge
was removed and replaced by fixed geometry between two plates which were placed perpendicularly. Also,
while estimating the approximate applied load (i.e. mass of the door) the material of the door was assumed
to be uniform and weights of minor parts including door handle, locks etc. were neglected. As for the
meshing, standard settings were used however the final mesh parameters were found by iterating the sizes
of elements until the results converged. In addition, the mesh control was applied to the weakest points to
get more accurate results
Model Information
Model name: Assem2

Current Configuration:
ALIKHAN SHAMBUL
29.11.2014
Solid Bodies
Document Name and
Reference
Cut-Extrude3
Treated As
Solid Body
Volumetric Properties
Document Path/Date
Modified
Mass:0.256583 kg
Volume:3.20729e-005 m^3
Density:8000 kg/m^3
Weight:2.51451 N
C:\moodle\3.0\3.0\BASE
MODEL_1.SLDPRT
Nov 26 21:34:20 2014
Mass:0.266264 kg
Volume:3.32829e-005 m^3
Density:8000 kg/m^3
Weight:2.60938 N
C:\moodle\3.0\3.0\BASE
MODEL_2.SLDPRT
Nov 26 21:34:22 2014
Cut-Extrude2
Solid Body
ALIKHAN SHAMBUL
29.11.2014
Study Properties
Study name
190N
Analysis type
Static
Mesh type
Solid Mesh
Thermal Effect:
On
Thermal option
Include temperature loads
Zero strain temperature
298 Kelvin
Include fluid pressure effects from SolidWorks

Flow Simulation
Solver type
Off
Inplane Effect:
Off
Soft Spring:
Off
Inertial Relief:
Off
Incompatible bonding options
Automatic
Large displacement
On
Compute free body forces
On
Friction
Off
Use Adaptive Method:
Off
Result folder
SolidWorks document (C:\moodle\3.0\3.0)
FFEPlus
Units
Unit system:
SI (MKS)
Length/Displacement
mm
Temperature
Kelvin
Angular velocity
Rad/sec
Pressure/Stress
N/mm^2 (MPa)
ALIKHAN SHAMBUL
29.11.2014
Material Properties
Model Reference
Properties
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Thermal expansion
coefficient:
AISI 316 Stainless Steel

Sheet (SS)
Linear Elastic Isotropic
Max von Mises Stress
Components
SolidBody 1(CutExtrude3)(BASE MODEL_1-1),
SolidBody 1(CutExtrude2)(BASE MODEL_2-1)
172.369 N/mm^2
580 N/mm^2
193000 N/mm^2
0.27
8000 g/cm^3
1.6e-005 /Kelvin
Curve Data:N/A
ALIKHAN SHAMBUL
29.11.2014
Loads and Fixtures

Fixture name
Fixture Image
Fixture Details
Entities:
Reference:
Type:
Translation:
Units:
Fixed-3
4 face(s), 1 plane(s)
Use reference geometry

0, 0, 0
mm
Resultant Forces
Components
Reaction force(N)
Reaction Moment(Nm)
X
1.11809e-006
0
Y
-4.63271e-007
0
Z
-9.53949e-007
0
Entities:
Type:
Resultant
1.54103e-006
0
5 face(s)
Fixed Hinge
Fixed Hinge-2
Resultant Forces
Components
Reaction force(N)
Reaction Moment(Nm)
X
-0.00333294
0
Y
0.0712515
0
Z
278.96
0
Entities:
Type:
Resultant
278.96
0
4 face(s)
Fixed Geometry
Fixed-5
Resultant Forces
Components
Reaction force(N)
Reaction Moment(Nm)
X
-0.00474381
0
Y
-0.159131
0
Z
-468.319
0
Resultant
468.319
0
ALIKHAN SHAMBUL
29.11.2014
Load name
Load Image
Load Details
Entities:
Type:
Coordinate System:
Remote Load
(Direct
transfer)-1
Force Values:
Moment Values:
Reference coordinates:
Components transferred:
1 face(s)
Load (Direct transfer)
Global cartesian
coordinates
---, ---, 190 N
---, ---, --- Nm
-17.5 -450 750 mm
Force
Connector Definitions
No Data
Contact Information
Contact
Contact Image
Contact Properties
Type: Node to node
Components: 1 component(s)
Global Contact
ALIKHAN SHAMBUL
29.11.2014
Mesh Information
Mesh type
Solid Mesh
Mesher Used:
Standard mesh
Automatic Transition:
Off
Include Mesh Auto Loops:
Off
Jacobian points
4 Points
Element Size
1.32 mm
Tolerance
0.066 mm
Mesh Quality
High
Remesh failed parts with incompatible mesh
Off
Mesh Information - Details

Total Nodes
303259
Total Elements
196308
Maximum Aspect Ratio
5.4474
% of elements with Aspect Ratio < 3
99.8
% of elements with Aspect Ratio > 10
% of distorted elements(Jacobian)
Time to complete mesh(hh;mm;ss):
00:00:16
Computer name:
DLPS55-451364
ALIKHAN SHAMBUL
29.11.2014
Mesh Control Information:

Mesh Control Name
Mesh Control Image
Mesh Control Details

Entities:
Units:
Size:
Ratio:
8 face(s)
mm
1.00734
1.5
Control-3
ALIKHAN SHAMBUL
29.11.2014
Sensor Details
No Data
Resultant Forces
Reaction Forces
Selection set
Units
Sum X
Sum Y
Sum Z
Resultant
Entire Model
-0.00811102
-0.0880987
-189.36
189.36
Reaction Moments
Selection set
Units
Sum X
Sum Y
Sum Z
Resultant
Entire Model
Nm
Beams
No Data
10
ALIKHAN SHAMBUL
29.11.2014
Study Results
Name
Type
Min
Max
Stress1
VON: von Mises Stress
4.13339e-012 N/mm^2
(MPa)
Node: 160227
71.2656 N/mm^2 (MPa)

Node: 150732
Assem2-190N-Stress-Stress1
Name
Type
Min
Max
Displacement1
URES: Resultant Displacement
0 mm
Node: 1
0.0024505 mm
Node: 5257
11
ALIKHAN SHAMBUL
29.11.2014
Assem2-190N-Displacement-Displacement1
Name
Type
Min
Max
Strain1
ESTRN: Equivalent Strain
1.68951e-017
Element: 136868
0.000229555
Element: 16870
12
ALIKHAN SHAMBUL
29.11.2014
Assem2-190N-Strain-Strain1
Name
Type
Min
Max
Stress2
P1: 1st Principal Stress
-14.5016 N/mm^2 (MPa)

Node: 82459
67.861 N/mm^2 (MPa)

Node: 150701
13
ALIKHAN SHAMBUL
29.11.2014
Assem2-190N-Stress-Stress2
Name
Type
Displacement1{1}
Deformed Shape
14
ALIKHAN SHAMBUL
29.11.2014
Assem2-190N-Displacement-Displacement1{1}
Name
Type
Min
Max
Factor of Safety1
Max von Mises Stress
2.41868
Node: 150732
4.17016e+013
Node: 160227
15
ALIKHAN SHAMBUL
29.11.2014
Assem2-190N-Factor of Safety-Factor of Safety1
Results & Conclusions

According to the obtained results from the simulation of the assembly it can be assured that the hinge will
not fail under the load of 190N. Also, as it was expected, the weakest parts of the assembly are located at
the holes and the largest displacements are located close to the fixture of pin.
Mesh refinement was applied in order to provide more accurate results of simulation. In a nutshell the main
idea of this method is that by changing the element sizes the increase of number on nodes and Von Mises
stress can be observed. Consequently, as the number of nodes for each iteration increases by at least 50% of
the previous value we need to obtain the change in Von Mises stress less than 5% of the previous value. The
table below shows the process of mesh refinement that was applied for this project
16
ALIKHAN SHAMBUL
29.11.2014
Nodes
1
2
3
4
5
6
7
8
18234
28321
46465
71488
117623
200981
303259
458602
Difference in
nodes(%)
55.32
64.07
53.85
64.54
70.87
50.89
51.22
Von Mises(MPa)
38.953
42.347
48.247
59.585
63.382
67.487
71.266
71.327
Difference in
Von Mises(%)
8.71
13.93
23.50
6.37
6.48
5.6
0.09
Element
size(mm)
4.02934
3.26377
2.5849
2.27472
1.85
1.55
1.32
1.13
As it can be seen from the result above the values for Von Mises stress converge at the eights iteration
because of that we use the 7th mesh adjustment for our analysis. The factor of safety that was obtained for
the load of 190N was found to be FS=2.419 which is safe enough taking into account the fact that the door is
assumed to be held on a single hinge. Thus, considering the fact that the doors are usually supported by at
least two hinges it can be stated that the design is appropriate. Furthermore, the combination of the same
hinges can be used in order to hold even heavier loads. As for the recommendations regarding improvements
in design the edges of the plates might be filleted to decrease the consumption of materials. Also, the
number of holes could be increased to make the fixture more stable. However, such actions might not be
beneficial from the economic perspective due to the fact that it requires more service work during
manufacturing process which requires more funds.
To sum up the project was considerably challenging yet interesting at the same time due to the fact that
students were actually able to apply the knowledge gained during the course. Also, understanding and using
of the finite element analysis technique in order to simulate the model was very beneficial from practical
point of view.
17

Door Hinge Design

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Simulation of Assem2

Loads and Fixtures................................... 6

Analyzed with SolidWorks Simulation

Model name: Assem2

Analyzed with SolidWorks Simulation

Analyzed with SolidWorks Simulation

Include temperature loads

Zero strain temperature

Include fluid pressure effects from SolidWorks

Incompatible bonding options

Compute free body forces

Use Adaptive Method:

SolidWorks document (C:\moodle\3.0\3.0)

Analyzed with SolidWorks Simulation

AISI 316 Stainless Steel

Analyzed with SolidWorks Simulation

Loads and Fixtures

Use reference geometry

Analyzed with SolidWorks Simulation

Analyzed with SolidWorks Simulation

Include Mesh Auto Loops:

Remesh failed parts with incompatible mesh

Mesh Information - Details

Maximum Aspect Ratio

% of elements with Aspect Ratio < 3

% of elements with Aspect Ratio > 10

Time to complete mesh(hh;mm;ss):

Analyzed with SolidWorks Simulation

Mesh Control Information:

Mesh Control Image

Mesh Control Details

Analyzed with SolidWorks Simulation

Analyzed with SolidWorks Simulation

VON: von Mises Stress

71.2656 N/mm^2 (MPa)

URES: Resultant Displacement

Analyzed with SolidWorks Simulation

ESTRN: Equivalent Strain

Analyzed with SolidWorks Simulation

P1: 1st Principal Stress

-14.5016 N/mm^2 (MPa)

67.861 N/mm^2 (MPa)

Analyzed with SolidWorks Simulation

Analyzed with SolidWorks Simulation

Max von Mises Stress

Analyzed with SolidWorks Simulation

Assem2-190N-Factor of Safety-Factor of Safety1

Results & Conclusions

Analyzed with SolidWorks Simulation

Analyzed with SolidWorks Simulation

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