Design of backdoor

AIM

To Design Back door with styling surface and use appropriate design methodologies, and provide the necessary reinforcements and embosses.

INTRODUCTION

• The back door is the rear of the vehicle. It may be used for loading and unloading cargo, or to get passengers in and out, in case there are seats present at the rear. The back door comprises of certain components which form the back door assembly togethether. In this back door also one of important safety for pedestrian and also pasengers safety.In this back door design following consideration to be followed.

• The material used in making the backdoor of the car is mainly steel. but, nowadays Aluminium is also used in making the panels.The main advantage of Aluminium is that the density of Aluminium is very less as compared to steel. so, it reduces the overall weight of the car. But Aluminium is more costly as compared to steel. In Aluminium is casting process and also no need for reinforcement.but, cost wise aluminium is high compared to steel.

DESIGN CONSIDERATION

• Rear Visiblity criteria
• Rear Crash Regulation
• Boot Space (Goods or Luggage space)
• Gap & Flushness Requirements.

COMPONENTS OF BACK DOOR :

• Back door outer panel upper
• Back door outer panel lower
• Back door inner panel
• Hinge Reinforcement Right side
• Hinge Reinforcement Left side
• Gas stay Reinforcemnt Right side
• Gas stay Reinforcement Left side
• Striker Reinforcement
• Wipor Motor Reinforcement

JOINING TECHNIQUES

• Mastic
• Spot welding
• Hemming

MASTIC

• Mastic is used for sealing and repair job on bodywork in the automotive
• It is used to fix the inner panel and outer panel which increases the NVH factor and stiffness of back door.
• mastic clearance is 5mm
• It has wheather strip for dynamic sealant

SPOT WELDING

• Spot welding is the fast process compared to any other welding process
• The purpose of spot welding is high reproducibility and automation are essential criteria.
• Spot welding has no clearance.

HEMMING

• Hemming is used to join inner and outer closure panels together.
• It has 0.2mm clearance.

BACK DOOR OUTER PANEL UPPER

BACK DOOR OUTER PANEL LOWER

BACK DOOR INNER PANEL

• Inner panel of the back door is important one and also first we create the sealing flange.and create emboss,cutout and reinforcement emboss.

SEALING FLANGE

Sealing flange is major role in back door for opening and closing position of the back door to be properly placed in the rubber sealant. Rubber sealnt available inside the car.

EMBOSS

Emboss is used to increase the strength of the body

RELIEF

Relief is used to avoid the stress concentration.

REINFORCEMENT

Reinforcement is defined as the support for the back door and also improve the stability and strength of the material.

Reinforcement we taken the material from scrap.

HINGE REINFORCEMENT

Hinge is to provide support and stability to the door and keep them intact as we open and close them.

GAS STAY REINFORCEMENT

Striker Reinforcement

WIPER MOTOR REINFORCEMENT

DRAFT ANALYSIS

BACKDOOR OUTER PANEL UPPER & LOWER

BACKDOOR INNER PANEL

HINGE REINFORCEMENT LH

HINGE REINFORCEMENT RH

GAS STAY REINFORCEMENT LH

GAS STAY REINFORCEMENT

STRIKER REINFORCEMENT

WIPER MOTOR REINFORCEMENT

TOOLING DIRECTION

BACK DOOR ASSEMBLY

RESULT

Thus, the Design Of Back door with styling surface and use appropriate design methodologies, and provide the necessary reinforcements and embosses to be satisfied.