Design of backdoor

OBJECTIVE: DESIGNING A BIW BACK DOOR OF CAR 

INTRODUCTION : 

the back door of the car is the rearmost part of the vehicle which gives access to the trunk space of the vehicle. the rear door also supports the reinforcement and added weights of the wiper motor, gas stay, tail lamp, and latch and striker. the back door is usually made of the inner and outer panels along with different reinforcement for portions like wiper motor latch and striker and also for the hinge placement area. Mostly aluminum and steel will be used but I also depend s upon the budget of the vehicle as lower budget cars use steel for production    

TOOLING DIRECTION 

• Before starting the design procedure of the inner panel of the back door the tooling direction is to be created for deep drawing purpose 
• Then we have to check the styling surface for any irregularity if there is any fix those irregularities 
• then the back door was designed using the top-down approach 

INNER PANEL BACK DOOR 

• After determining the tooling direction sealing flange is to be created by checking all the boundaries and by following the shape of the inner panel design 
• after the creation of the inner panel we have to create the components like hinge, latch, and striker, gas-stay emboss, and their reinforcement in a top-down method 
• the purpose of creating emboss is to take the damage first in case of an accident 

MASTIC SEALANT 

 

• The mastic sealant is used to fix the inner panel with the outer panel which increases the NVH factor and stiffness of the backdoor

HINGE AND GAS STAY EMBOSS 

• UPPER EMBOSS SHOWS THE HINGE EMBOSS 
• THE LOWER LEFT EMBOSS SHOWS THE GAS-STAY EMBOSS

 LATCH AND STRIKER EMBOSS 

• Latch and striker emboss were  created only after creating latch and striker trajectory which follows the opening and closing of the back door while making the hinge axis the baseline

DRAFT ANALYSIS 

• the draft analysis will be performed to check for the manufacturability of the part where the tooling direction is the one we created initially 
• The green portion represents that manufacturing of the  part is possible 

HINGE REINFORCEMENT 

• Reinforcement is created using the linked body in the top-down assembly method 
• reinforcement is given to the part to increase the strength if that region 

GAS-STAY REINFORCEMENT 

• Reinforcement is created using the linked body in the top-down assembly method 
• reinforcement is given to the part to increase the strength of that region 

WIPER-MOTOR REINFORCEMENT 

• Reinforcement is created using the linked body in the top-down assembly method 
• reinforcement is given to the part to increase the strength of that region 

LATCH AND STRIKER REINFORCEMENT 

• Reinforcement is created using the linked body in the top-down assembly method 
• reinforcement is given to the part to increase the strength of that region 

 BACK DOOR PUTER PANEL 

• The back door was created using the styling surface 
• the outer panel is created in two different parts called as upper outer panel and lower outer panel 
• after creating the panel necessary hemming and reliefs were given 

HEMMING 

CORNER RELIEF 

CONCLUSION 

The BIW of the back door was created by following engineering standard and also the deep drawing requirement was also met