Design of backdoor

AIM

Use the provided styling surface to come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcement and embosses

BACK DOOR

It is the door which is located at the rear side of the car and it provides access to the boot space, doors can be operated manually or electrically powered. In most of the luxury car doors are operated electrically

Types Of Doors Based on Working Position

Top mounted doors

Doors are mounted on the top region

Side mounted doors

Doors are mounted at the side

Bottom\split type doors

Doors are mounted on bottom side ore mounted as shown in figure below

Types Based on Working Mechanism

Gas stay type

It is the most commonly used tailgate mechanism for lower segment to luxury segment cars

Powered lift system

It is another sophisticated way of trunk opening mechanism which is automatically opened and closed at the touch of a button

SHEETMETAL PROCESS USED FOR MANUFACTURING THE BACK DOOR

Deep drawing

This process is an effective method of manufacturing of cups, cans and other similar deep drawing products. Deep drawing has two main categories

First-stage drawing: the blank shape of metal is placed on the die and contact with the product. When thew metal specimen is flat piece of sheet metal used in forming and finish the products. Initially punch moves in downward direction. The outer rim of blank is subjected to pure radial drawing between die and blank metal. The metal becomes a bend and sliding over die and also stretched between die and punch. The metal in the vicinity of the punch head and contact with it bend and slide over radii and stretch over punch head.

Redrawing: the component drawn from first stage again it is redrawn convert into more depth to form a cup shape in the die and punch. The second stage of drawing is called redrawing

Embossing

Embossing is a metal forming process for producing raised or sunken designs or reliefs in sheet material, this helps in increasing the strength of the produced part

Hemming

Hemming is a operation in which the edges of the sheet are folded over another part in order to achieve a tight fit. Normally hemming operation are used to connect parts together, to improve the appearance of a part and to reinforce part edges

Types of hemming operations

Conventional die hemming: flanges is folded over the entire length with a hemming tool

Roll hemming: the hemming rollers is guided by an industrial robot to form the flange

Types of hems

Flat hem

Open hem

Rolled hem

Teardrop hem

Rope hem

Blanking

It is cutting operation of a flat sheet metal and the article punched out is known as blank (required product) and the material left behind is considered as waste

Punching

It is similar to blanking only the main difference is that, the hole is the required product and the material punched out from the hole is considered as waste

Spot Welding

Spot welding involves using heat produces by resistance to an electrical current to join materials together. The current heats the material to a point where they become malleable. The use of strong pressure bond them together

BACK DOOR DESIGN

Door Part Thickness

Outer panel: - 0.75mm

Inner panel: - 0.75mm

Reinforcements: - 1.5mm

Given data

Given file is repaired and tooling axis is created

Inner panel is created with 0.75mm thickness providing embosses, openings and screw holes

Draft analysis of inner panel

Outer panel upper part is created with 0.75mm thickness hemming is also done for fixing it to the inner panel

Outer panel lower part is created with 0.75mm thickness hemming is also done for fixing it to the inner panel

Then reinforcement for hinge gas stay wiper motor and latch and striker fixing is made

Hinge reinforcement

Gas stay reinforcement

Wiper motor reinforcement

Latch and striker reinforcement

Final Assembly

CONCLUSION

Thus, the design of back door using appropriate design methodology and providing necessary reinforcement and embosses are done