Design of back door using CATIA V5

AIM:

To develop automotive back door using CATIA tool.

Design requirements:

outer upper and lower panel reference.

Tool used:

CATIA V5

Components in Back Door:

• Inner panel
• Outer Upper Panel
• Outer Inner Pannel
• Reinforcements

Design considerations:

• Rear visibility
• Latch & Striker reinforcement
• Hinge &Gas stay reinforcement

Theory:

Back door is also called as tailgate, which is most important for rear visibility criteria and it allows access to boot space, more the thinner the back door more the boot space we get.

For back door to prepare we need outer panel reference, we have to prepare inner pane.

back door can be made by two materials Aluminium or Steel.

Aluminium back doors are good at strength and also as their density is less it can improve the performance of automobile.but the only disadvantage is the are costly.

here are the some differences od both materials.

with aluminium entire inner panel can be deep drawn but we cannot do this with steel cause of its ductility.here is the weight difference of the back door made with two materials.

There is a drastic change in weight in the aluminium of 4.7kg.

Nowadays many companies stared using aluminium for this.

This are some Benchmarks results of aluminium.

Assembly sequence of the aluminium back door.

Design of Back door :

Inner Pannel:

Inner panel acts as the large reinforcement of the Tailgate and embosses are made in such a way that when the automobiles crash maximum force is travelled to the hinge side by safeguarding the passenger.

The Flange gives additional strength to the tailgate it extends up to the styling surface and sticks up with mastic.

Inner panel has all the support structures like hinge stays, gas stays, wiper motor, latch &Striker.

Reinforcements for the Hinges, gas stay, wiper motor, latch & Striker.

Reinforcements are added at the weak spots of the panel to give them additional strength.

Backdoor outer upper and lower panels.

Hemming:

Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming is the process in which the edge is rolled flush to itself, while a seam joins the edges of two materials.

Hemming for both upper and lower panel with relief.

Assembly of the back door:

Draft Analysis:

Evaluates whether a part has adequate taper to allow it to be removed from its mould. If you create shapes or parts that need to be moulded, the draft analysis tool evaluates whether the draft angles on the part make it possible to remove the part from the mold.

If the part which undergoes draft analysis gives good result then the component is ready for manufacturing.

this can be known by seeing colours if the part is in green then the part is completely fine.

If the part is showing blue then there is a minor error, if it shows red then we have to again change the dimensions and develop the part again until it shows green.

Here it is completely green that means the part is good for manufacturing.