Design of backdoor
Aim: To come up with a back door design using the provided styling surface by using appropriate design methodologies, and providing the necessary reinforcements and embosses.
Back Door/Tailgate:
Back door or tailgate is the rear door of the car which opens either upwards or sideways providing access to the luggage/boot area.
The various parts of the back door have been mentioned in the figure below.
What is Gas Stay?
Gas stays are the piston-like hinges that support the tailgate at either side when opened. It makes lifting and closing the lid much easier.
Challenge:
Given styling surface
The styling surface given is of the back door outer panel which has been split by half. For working on the inner panel, this one half should be used and the remaining half can be easily mirrored.
Tooling Axis Creation
Making of Sealing Flange
Offsetting outer panel inwards for 25mm
Now using parallel curves and split command, we make a thin layer of surface. A sweep is done from this surface and it is then trimmed with the outer panel.
CREATING MULTISECTION
Making embosses
The hole at the top above the big emboss is where there will be a provision given for mastic point interjection between the outer panel and inner panel.
UPPER EMBOSS
LOWER EMBOSS
The hole at the top above the big emboss is where there will be a provision given for mastic point interjection between the outer panel and inner panel.
CREATE A LANCING:
CREATE A HINGE
CREATE GAS STAY
CREATE A W
WIPER MOUNTING
CREATE A STRIKER
Final inner panel
Thickening inner panel outwards to 0.75 mm
DRAFT ANALYSIS OF INNER PANNEL
Making of Reinforcements
Reinforcements can be made by extracting the surface of the inner panel and thickening them to 1.5 mm.
Hinge Reinforcement
GAS SATAY REINFORCEMENT
REINFORCEMENT OF WIPER MOUNTING
REINFORCEMENT OF STRIKER
Hemming on the Outer Panel
The hemming was started by making an offset of 2.65 mm inwards. A sweep was made from the outer panel and these 3 surfaces were joined together using bi-tangent fillet (1.3 mm) command.
SWEEP
TRITANGENT FILLET
FINAL PRODUCT
Conclusion: The back door inner panel with its various reinforcements was successfully made following the design rules and guidelines. Draft analysis was also done for each part.
FAMILY TREE
