Abstract
Environmental issues are attracting increasing interest worldwide, and accordingly, environmental regulations for vehicles are being made more stringent. As a result, the car industry is conducting studies focusing on fuel efficiency and lightweight vehicles. To manufacture lightweight vehicles, existing steel parts are replaced by composite materials and lightweight metals. In this study, the fatigue life of a new material for manufacturing lightweight car door hinges was predicted using a finite-element analysis program. The existing steel material was replaced by carbon-fiber-reinforced plastic (CFRP) and aluminum alloy 6061, and the test results were analyzed. The maximum stress decreased by approximately three times, whereas the fatigue life and safety factor increased. When only CFRP was used, its allowable stress, safety factor, and fatigue life were excellent, but the sagging of the product exceeded the allowable value, which posed a limitation in use. Therefore, it seems desirable to use an appropriate combination of steel, AA6061, and CFRP for this product.
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