Investigation on the Manufacturing, Testing, and Simulation Processes of the Hood Hinge Assembly

The automotive industry is currently undergoing significant transformations driven by challenges such as fierce competition, supply chain disruptions, and stringent legislative regulations aimed at reducing pollutant emissions. The research employs a combination of theoretical analysis and numerical modeling to investigate the manufacturing processes of stamped automotive components. Data collection methods include experimental testing of materials, LS-DYNA simulations, and non-contact scanning for dimensional analysis. The study also utilizes a workflow diagram to illustrate the various phases involved in the design and validation of automotive assemblies. The findings detail the critical role of digital transformation in the automotive industry, particularly in enhancing the accuracy and reliability of manufacturing processes. Implementing digital twins improves product quality and reduces product development time. The experimental results were compared with simulation data, and a good correlation was identified, showing, for the numerical model with complete history (thickness and stress), a difference of 1.6%. Furthermore, to simplify the process of developing the numerical models for the initial iterations, a scale factor of ~1.1 is proposed for the testing load. This factor is not limited to the current design, as the manufacturing stages are similar for this range of products.