OPTIMIZATION OF POLYMER STAKE GEOMETRY BY FEA TO ENHANCE THE RETENTION FORCE OF AUTOMOTIVE DOOR PANELS

This study focused on optimizing retention geometries for automotive interior door panel assemblies using ultrasonic welding, a preferred technique due to its strength and clean aesthetic appearance. The research aimed to resolve the conflict between tight spatial constraints and the need to maintain structural integrity during side-impact collisions. Using a Design of Experiments approach based on the Taguchi L8 method, four key parameters were evaluated: height, length, number of reinforcements, and component clearance. Models designed in the computer and developed in Siemens NX were validated through finite element analysis to quantify stiffness, maximum retention force, and stress concentration using different ANSYS software. The optimized configuration – featuring a 10 mm height, 15.5 mm length, three reinforcements, and 0.5 mm clearance – increased strength by 33.8% (234.2 N vs. the traditional 175 N design) while reducing the required manufacturing area by 74%.