Design of backdoor

Report Back panel

Available part file verified and found few disjoint in panel. Each joint cross verified and smoothened by using ‘Face Blend’.

Back upper and lower panels were in separate condition, a flange has been created to perpendicular to both of the panels, with zero clearance.

Separate part file has created for upper panel and lower panel. Assembly file has been crated and two above mentioned part files were merged.

Offset was created to make proper packing region in inner panel. By using bridge curve, surfaces were joint together to create smooth and liner packing region.

A width of 25mm provided for packing region by considering rubber deformation while back door comes to contact.

30 mm offset were created from the edge of panels.

By considering the shape of back door panel, a tooling direction has been created. According law extension has created to develop surface between packing region and back door inner panel.

Shape edged were smoothened by using Face blend.

By considering the moment could be created in a vehicle due to collision, Emboss has been created and supporting sheet has created by giving space for mastic joint.

Separate space given for tail lamp installation purpose.

Hemming surface created by using offset surface and face blend.

Both upper and lower panels are thickened to check the workability.

Mirror Assembly was used to completed back door assembly.