THE FEDERAL UNIVERSITY OF TECHNOLOGY, AKURE

P.M.B. 704, ONDO STATE, NIGERIA.

A REPORT ON

THE ANALYSIS AND REDESIGNING OF A CONVENTIONAL DOOR HINGE

WRITTEN BY

FOLORUNSO DAVID OLUWAPELUMI

(MEE/18/6952)

SUBMITTED

TO

PROF. T.I. OGEDENGBE

THE DEPARTMENT OF MECHANICAL ENGINEERING, SCHOOL OF

ENGINEERING AND ENGINEERING TECHNOLOGY,

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF

BACHELOR OF ENGINEERING (B. ENG.) DEGREE IN MECHANICAL

ENGINEERING.

APRIL, 2024
 TABLE OF CONTENTS
LIST OF FIGURES ...................................................................................................................... 2

ABSTRACT ................................................................................................................................... 3

CHAPTER 1 .................................................................................................................................. 4

1.0 INTRODUCTION TO DESIGN FOR MANUFACTURE AND ASSEMBLY (DFMA) ... 4

1.1 DOOR HINGE ...................................................................................................................... 5

1.2 DESIGN STRUCTURE OF A DOOR HINGE .................................................................... 6

1.3 STRUCTURAL FACTORS THAT AFFECTS THE DESIGN OF A DOOR HINGE ........8

1.4 AIM AND OBJECTIVES .....................................................................................................9

CHAPTER 2 .................................................................................................................................. 9

2.0 LITERATURE REVIEW ......................................................................................................9

CHAPTER 3 ................................................................................................................................ 11

3.0 METHODOLOGY ..............................................................................................................11

CHAPTER 4 ................................................................................................................................ 14

4.0 RESULT AND DISCUSSION ............................................................................................14

CHAPTER 5 ................................................................................................................................ 16

5.0 CONCLUSION ................................................................................................................... 16

REFERENCE .............................................................................................................................. 17

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 LIST OF FIGURES

Figure 1.0: A conventional door hinge ..………………….…………………………………5

Figure 1.1: Structural breakdown of a conventional door hinge ………...……………….…7

Figure 3.0: Exploded view of redesigned door hinge ………….………...…………………12

Figure 3.1: Full view of redesigned door hinge ………………..………...…………………13

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 ABSTRACT

Designing and making door hinges following DFMA principles makes them more efficient and

cost less. This article talks about how DFMA helps design door hinges that are cheaper, stronger,

and last longer. By using DFMA methods, manufacturers can make better door hinges that are

easier to put together and use less material. A transition from a door hinge with a hinge pin

acting as a separator between the two leaves and so many knuckles on both hinge leaves to an

integration of both leaves and hinge pin with fewer knuckles and lesser numbers of fasteners

illustrates the benefits, including simplified assembly, space optimization, standardization, and

enhanced robustness. This makes assembly easier, saves space, and makes the hinges stronger.

Leveraging tools like SolidWorks software, this redesign signifies a significant advancement in

manufacturing efficiency, assembly simplicity, and product performance. By making things

simpler, using fewer parts, manufacturers save money, make things faster, and make better

hinges overall.

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 CHAPTER 1

1.0 INTRODUCTION TO DESIGN FOR MANUFACTURE AND ASSEMBLY (DFMA)

Design for Manufacture and Assembly (DFMA) is a method used in engineering and design to

make manufacturing and assembly easier. It's all about making products in a way that's simple,

saves money, and makes everything run smoothly. By thinking about how things are made right

from the start, DFMA helps create products that are cheaper to produce but still work great.

DFMA has two main parts: design for manufacture (DFM) and design for assembly (DFA).

DFM is about making sure the product is easy to make. This means picking materials and ways

to make things that are cheap and easy, using as few parts as possible, and making sure

everything is simple to put together.

DFA, on the other hand, is about making the assembly process easy. This involves making sure

the product is simple to put together, needing as few steps as possible, not needing special tools

or skilled workers, and making sure all the parts fit together nicely.

When DFM and DFA are used together, companies can enjoy lots of benefits like faster

production times, cheaper materials and labor costs, better product quality, and being able to

respond to customer needs more easily.

DFMA is used in lots of different industries like cars, planes, electronics, and everyday items.

Companies use special software and testing to check designs, find any issues with making or

assembling the product, and make changes to improve things.

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Overall, DFMA helps designers and engineers create products that are not only clever and work

well but also easy and cheap to make, which helps companies be more successful and make more

money in today's competitive world.

1.1 DOOR HINGE

Door hinges are essential components of any building structure, providing the necessary support

for doors to open and close smoothly. They are fundamental components of doors, serving as the

mechanism that enables them to swing open and closed smoothly while providing support and

stability. They are essential for the functionality, security, and aesthetics of doors in various

settings, including residential, commercial, and industrial environments.

Comprising of several components, a typical door hinge consists of hinge leaves, hinge pins, and

knuckles. Hinge leaves are flat, elongated metal plates that are attached to the door and door

frame. The hinge pin, a cylindrical rod or shaft, acts as the pivot point for the hinge leaves,

allowing rotational movement. Knuckles are cylindrical sections that connect adjacent hinge

leaves and facilitate the rotation of the door.

Fig 1.0: A conventional door hinge

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Door hinges are crucial for the functionality, security, and aesthetics of buildings. They enable

doors to swing open and closed smoothly, ensuring easy accessibility and usability. Additionally,

hinges play a vital role in building security by securely attaching doors to door frames,

preventing unauthorized access and enhancing overall safety. In emergency situations like fires

or evacuations, hinges facilitate swift and unobstructed exits, ensuring occupants can leave

buildings quickly and safely.

Furthermore, well-designed hinges enhance the visual appeal of buildings, complementing their

architectural style and decor across residential, commercial, and industrial settings.

1.2 DESIGN STRUCTURE OF A DOOR HINGE

The design structure of a conventional door hinge is a complex arrangement of components

meticulously engineered to facilitate the smooth operation of doors while ensuring stability,

durability, and aesthetic appeal. At the heart of the hinge are the hinge leaves, which are flat,

elongated metal plates affixed to both the door and the door frame. These leaves serve as the

foundational elements upon which the entire hinge assembly rests.

Central to the functionality of the hinge is the hinge pin, a cylindrical rod or shaft that acts as the

pivot point around which the door rotates. Inserted through holes or knuckles in the hinge leaves,

the hinge pin provides the necessary axis for the door to swing open and closed with ease.

Complementing the hinge pin are the knuckles, cylindrical sections that connect adjacent hinge

leaves, facilitating smooth rotation while maintaining structural integrity.

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 Fig 1.1: Structural breakdown of a conventional door hinge

The assembly of the hinge is secured through the use of fasteners, typically screws or bolts,

which firmly attach the hinge leaves to both the door and door frame. These fasteners ensure

stability and prevent any movement or displacement during operation. To further enhance

functionality and longevity, some hinge designs incorporate bushings or bearings to reduce

friction and wear between the hinge pin and leaves. These components contribute to smoother

operation and prolonged lifespan of the hinge assembly.

In addition to functionality, door hinges also play a significant role in the aesthetic appeal of

buildings. Finishes and coatings such as zinc plating, chrome, or powder coating are applied to

door hinges to enhance durability, corrosion resistance, and visual appearance. These finishes

protect the hinge components from environmental factors while adding a decorative touch that

complements the overall design of the door and surrounding architecture.

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The design structure of a conventional door hinge is a sophisticated combination of components

engineered to provide reliable support, smooth operation, and aesthetic appeal. By carefully

integrating these elements, door hinges ensure the functionality, security, and visual appeal of

doors in various architectural settings.

1.3 STRUCTURAL FACTORS THAT AFFECTS THE DESIGN OF A DOOR HINGE

There are several structural factors that influences the design and performance of a door hinge,

and they include the following:

1. Material Selection: Door hinges are commonly made from materials such as steel, brass, or

stainless steel, chosen for their strength, durability, and corrosion resistance.

2. Load-Bearing Capacity: The hinge must be capable of supporting the weight of the door and

any additional loads, such as heavy-duty doors or high-traffic environments.

3. Size and Dimensions: The dimensions of the hinge leaves, hinge pin, and fasteners are

carefully selected to ensure compatibility with the door and frame dimensions.

4. Durability and Wear Resistance: Door hinges are subjected to frequent use and

environmental factors, requiring materials and finishes that can withstand wear and tear over

time.

1.4 AIM AND OBJECTIVES

The aim and objectives of this report is to analyse and redesign the structure of a conventional

door hinge system for efficient manufacturing and assembling of parts.

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 CHAPTER 2

2.0 LITERATURE REVIEW

Conventional door hinges represent a fundamental yet critical component in architectural design,

facilitating the seamless operation of doors while ensuring stability, durability, and aesthetic

appeal. The integration of Design for Manufacture and Assembly (DFMA) principles in the

design of these hinges has garnered significant attention in recent years, aiming to optimize

manufacturing processes, reduce production costs, and enhance product efficiency.

One of the key components of a conventional door hinge is the hinge leaves, which serve as the

foundational elements upon which the entire hinge assembly rests. Through the application of

DFMA principles, researchers have explored strategies to simplify the design of hinge leaves,

minimizing the number of parts and assembly steps required while maintaining structural

integrity and functionality.

The hinge pin, another essential element of the hinge assembly, acts as the pivot point around

which the door rotates. DFMA principles have been utilized to optimize the design of hinge pins,

focusing on factors such as material selection, geometric configuration, and manufacturing

process to minimize production complexity and cost.

Knuckles, cylindrical sections that connect adjacent hinge leaves, play a crucial role in

facilitating smooth rotation and maintaining structural integrity. Researchers have investigated

various DFMA strategies to simplify the design of knuckles, such as reducing the number of

components or integrating multifunctional features to streamline manufacturing and assembly

processes.

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In addition to component-level optimizations, DFMA principles have been applied to the overall

assembly of conventional door hinges. By identifying opportunities to reduce part count,

minimize assembly time, and enhance manufacturability, researchers have demonstrated the

potential for significant cost savings and efficiency improvements in hinge production.

While the adoption of DFMA principles in conventional door hinge design offers numerous

benefits, challenges and limitations remain. Design complexity, trade-offs between cost and

functionality, and the need for specialized manufacturing capabilities are among the factors that

researchers continue to address in their quest to optimize hinge performance and efficiency.

In conclusion, the integration of DFMA principles in the design of conventional door hinges

represents a promising avenue for improving product efficiency, reducing manufacturing costs,

and enhancing overall customer satisfaction. Through ongoing research and innovation, the

optimization of hinge design and production processes will continue to shape the future of

architectural hardware.

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 CHAPTER 3

3.0 METHODOLOGY
The previous design of a conventional door hinge typically utilized a hinge pin, which is a

cylindrical rod that connects both hinge leaves together via the aid of a knuckle, which can be

found on both hinge leaves. This design however had several drawbacks in terms of

manufacturing and assembly efficiency:

1. Complexity in design: Conventional door hinges often involve multiple components and

intricate designs, that leads to increased complexity in manufacturing and assembly

processes. This complexity can result in higher production costs and longer lead times.

2. High part count: Conventional door hinges may consist of numerous parts, including

hinge leaves, pins, knuckles, fasteners, and additional components. A high part count

complicates assembly and increases the risk of errors during manufacturing.

3. Difficulty in assembly: Assembling conventional door hinges with multiple components

can be labor-intensive and time-consuming. Each part must be correctly aligned and

secured during assembly, increasing the likelihood of errors and requiring skilled labor.

4. Limited standardization: Lack of standardization in conventional door hinge designs can

make it challenging for manufacturers to optimize production processes and achieve

economies of scale. Customization requirements for different door sizes and styles further

complicate manufacturing and inventory management.

By applying Design for Manufacture and Assembly (DFMA) principles to the design of door

hinges, we can streamline the manufacturing and assembly process while enhancing product

performance and reliability. Using SolidWorks software, we can redesign the door hinge

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arrangement to incorporate lesser number of knuckles on both sides of the hinge leaves. This

design change offers several advantages:

1) Simplified Design: Reducing the number of knuckles simplifies the overall hinge design,

leading to fewer components and potentially less complex manufacturing processes. This

simplification can result in cost savings and increased efficiency during production.

2) Improved Durability: With fewer knuckles, there are fewer points of potential failure in the

hinge assembly. A simplified design reduces the risk of wear and tear on individual

components, enhancing the overall durability and longevity of the hinge.

3) Reduced Friction and Wear: Fewer knuckles mean fewer points of contact between hinge

components, resulting in reduced friction during door operation. This can lead to smoother

door movement and decreased wear on the hinge assembly over time, ultimately extending

the lifespan of the hinge.

4) Easier Maintenance: Simplifying the hinge design by reducing the number of knuckles can

make maintenance tasks easier and more straightforward. With fewer components to inspect

and maintain, upkeep becomes less time-consuming and labor-intensive.

Fig 3.0: Exploded view of redesigned door hinge

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 Fig 3.1: Full view of redesigned door hinge

Leveraging SolidWorks software and incorporating DFMA principles into the design process, we

can achieve significant improvements in manufacturing efficiency, assembly simplicity, and

product performance for door hinges. This transition from door hinges with multiple number of

knuckles to a lesser number of knuckles is a strategic advancement towards optimizing both the

manufacturing process and the end-user experience.

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 CHAPTER 4

4.0 RESULT AND DISCUSSION

knuckles to lesser knuckles can impact the manufacturing and assembly process which in turn

can lead to the optimization of the manufacturing process, thus enabling productivity. However,

taking into consideration the structural factors that influences the design of a conventional door

hinge, reducing the number of knuckles, no matter how beneficial it might be can pose

significant drawbacks in a door hinge. But that notwithstanding, these drawbacks can be

mitigated.

Fewer knuckles may result in a hinge assembly with a lower load-bearing capacity. This could be

a concern in applications where heavy doors or high-traffic areas require hinges capable of

supporting significant weight over time. However, choosing high-quality materials with superior

strength and durability can help compensate for the reduced load-bearing capacity of hinges with

fewer knuckles. Opting for materials such as stainless steel or reinforced alloys can ensure that

the hinge assembly maintains sufficient structural integrity under heavy loads.

Also, a door hinge with fewer knuckles could lead to increased stress on the remaining

components, such as the hinge leaves and fasteners. Thus, incorporating reinforcement features,

such as thicker hinge leaves can help strengthen the hinge assembly and mitigate the risk of

stress concentration on remaining components.

The primary purpose of applying Design for Manufacture and Assembly (DFMA) principles to

the design of a door system is to optimize the manufacturing process, reduce production costs,

and enhance product efficiency. Reducing the number of knuckles a door hinge has can achieve

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this, but at the same time it comes with its uncertainties. Thus, by implementing these strategies

discussed, manufacturers can effectively mitigate the drawbacks associated with a door hinge

having a lesser number of knuckles, ensuring that the hinge assembly maintains optimal

performance, durability, and reliability in diverse applications.

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 CHAPTER 5

5.0 CONCLUSION
The transition from multiple knuckles to fewer knuckles in a door hinge design represents a

significant leap forward in manufacturing efficiency and assembly simplicity. Through the

application of Design for Manufacture and Assembly (DFMA) principles and leveraging tools

like SolidWorks software, manufacturers can realize tangible benefits across various aspects of

the production process.

By streamlining manufacturing processes, reducing component count, and standardizing

components, manufacturers can achieve cost savings, shorten lead times, and improve overall

production efficiency. The simplified assembly steps and enhanced quality control measures

result in greater consistency, reliability, and customer satisfaction.

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 REFERENCES

Boothroyd, G., Dewhurst, P., & Knight, W. (2010). “Product Design for Manufacture and
Assembly.” CRC Press.

Ulrich, K. T., & Eppinger, S. D. (2011). “Product Design and Development.” McGraw-Hill
Education.

Boothroyd, G., & Dewhurst, P. (2014). “Design for Assembly Handbook.” CRC Press.

Yang, T., & Zhang, Y. F. (2012). “Application of DFMA in product design of automotive door
hinges.” In Advanced Materials Research (Vol. 486, pp. 1483-1486). Trans Tech Publications
Ltd.

Varghese, K., & Pandey, P. M. (2013). “A study of design for manufacturability and assembly
for automotive door hinges.” In Proceedings of the International Conference on Industrial
Engineering and Operations Management (IEOM) (pp. 1064-1072).

Ibaraki, S., Takeuchi, K., & Togawa, T. (2018). “Product design for manufacturability and
assembly: a comprehensive approach to controlling the cost of manufacture.” Springer.

Chen, Y. H., & Liang, S. Y. (2012). “Design for manufacturing and assembly of automotive
door hinges.” Journal of Mechanical Science and Technology, 26(11), 3659-3666.

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