Design of backdoor

OBJECTIVE:- To design the back door by given class surface of outer pannel of back door.

Theory- It is the type of door which is located back side of the vehicle. which are use to access luggage compartment of vehicle. The component of back door-

1.  outer pannel of back door- It is skin styling surface consist of to part upper outer pannel & lower outer pannel join by spot welding 
2. Inner pannel of back door - it is inner side of back door where mounted wiper moter, gass stay some other component 
3. gass stay- It is important part of  back door and there location deside the openinig angle of back door If location is tend to upper side opening angle is more and tend to lower side opening angle less than position of gass stay important criteria of desining.
4. latch striker- The position latch striker gives trejectory of open and close of outer pannel

        Types of back door:-

• Top mounted - These type of back door are uses in modarn suv, luxury cars
• Side mounted - These type back door are easier compare to top mounted car and uses van type MPVs, SUV and Pickup vehicle
• Bottom mounted - These type back door use estate type cars, pickup truck and some luxury cars

METHODOLOGY:- 

Given skin surface

                                             

                                                                                      upper outer pannel

                                             

                                                                                    lower outer pannel

Design consideration :-

• Minimum draft angle should be positive 7 degree
• Minimum radius of curvature should be 3.75mm
• Thickness of outer and inner pannel is 0.75 mm
• The gap for mastic is 5mm
• The gap in heming for glue is 0.2 mm
• Thickness of rainforcement is 1.5 mm 

Inner pannel view

                    

 Manufacturing process of inner pannel :-

• Deep drawing- It is metal forming process inwhich sheet metal is deform into forming die by mechanical action through punch. depth of deformation is exceed the diameter is called deep drawing. sealing and back door shape are drawn in die as shown.

                                                

• punching operation- In this operation material are remove from sheet metal though apply great cutting force. In inner pannel windshield and some cutout are drawn from this operation.
• Emboss operation- In this operation produce raise pattern of surface of metal. In inner pannel hing emboss, gass stay imboss, wiper motor emboss and latch striker emboss are drawn shown below-

             

           

Latch striker tejectory:- It is the open and close tejectory of back door. which is drawn from centre axis of hing as shown-

                                                          

Reinforcement:- It is the use to strength the sheet. In back door provided hing reinforcement, gass stay reinforcement, latch striker reinforcement and wiper moter reinforcement are shown-

   

      

Joining process- outer pannel and Inner pannel are join by following process

• hemming process - Upeer outer pannel and inner pannel are join by hemming. sheet are formed in U shape through roller shown   

                                

• Mastic sealan-Upeer outer pannel and inner pannel are join through sealan in centre region as shown

                                           

 Draft analysis:-

                                     

Conclusion :- Design of back door at given skin section are shown