Design of backdoor

BACK DOOR DESIGN

Introduction

The Back Door of an Automobile, also called the Tailgate, is on the backside of the Car. It is the door to the luggauge compartment, a passenger shield against rear collisions and weather, the backside wind shield, the Rear Window housing and the Rear Wiper Motor Housing. Back Doors are less frequently used in than the Side Doors but they undergo Slamming. They also play an important role in the aesthetics of the Car.

Manufacturing Process

Much like the Side Door Panels, the Inner And Outer Panels are Stamped out using Sheet Metal made of steel or Aluminium. Deep drawn stamping refers to the process of forming sheet metal under compressive and tensile conditions to into a cavity, producing a closed bottom, round, or irregularly shaped Sheet metal. The material is actually forced into a plastic state as it is dragged over the die radius and down into the die. This compression process is done under calculated and very controlled conditions involving blank-holding pressures, punch and die radii, punch speed, and lubrication. The end result creates a hollowed vessel, which can be any shape in nature.

Here, the Outer Panel is made from part disintegration or Part Separation Where the Panel is stamped out in two or more parts and then SPOT Welded Together. The Inner Panel is Considerably More complex than in the side doors. It may require more than one stamping operation, first draw for all Door Hardware and Reverse Draw for all the indentations requird for Assembly Access and Fastening. The Outer and Inner Panet are Joined together through Roll Hemming(3 passes). The Gas Stay and Hinge Regions have a reinforcement for adding strength. There are also the adding of embosses to reinforce weaker regions which are information collected though Analysis and live tests. Holes need to Stamped out for the installation of Headlights and Wiper motor, etc. Lastly, There is an emboss for the Latch.

The Back Door Model

Full Assembly of BackDoor: Outer Panel, inner panel, Hinge Reinforcement(Left and Right), Gas Stay Reinforcement(Left and Right)

Inner Panel

Inner Panel with Blanked Portions for Installation of Headlight and Wiper Motors and Other wire Harnesses.

Outer Panel

Consists of Upper and Lower Part flanges Spot Welded together to achieve Aesthetics and Strength.

Gas Stay and Hinge Reinforcement

Reinforcement of Walls where there is Gas Stay and Hinge Mounting Region

Hemming with Reliefs

Relief is given at every sharp turn at the edges.

THE DRAFT ANALYSIS

Draft Analysis of the Inner Panel is mostly green(Pass). Taken in the Drawing Direction Shown Below.

Conclusion

The Back Door is Successfully Modeled. Improvements can be made in the Emboss and Mastic Points Area.