Design of backdoor

                                                             PROJECT REPORT OF BACK_DOOR DESIGN

OBJECTIEV:By using the given styling surface to design a automotive back door design, use appropriate design                                     methodologies, and provide the necessary reinforcements and embosses to the backdoor.

Styling Surface:

SOFTWARE USED: NX Cad.

INTRODUCTION:The backdoor of an automotive is located at the rear side of the automotive which gives access for the                                 boot space to store luggage, spare wheel etc.

Backdoor can be open and close manually or by electric powered. In most of the luxury cars door is electrically operated.

 The material used for door manufacturing depends on the budget and performance of the vehicle. Mostly Aluminium and Steel will be used whereas low-budget vehicles use Steel which makes the manufacturing process easy and cost-efficient since it follows the Stamping of Moulds.

DESIGN CONSIDERATION FOR DESIGN OF BACKDOOR:

• Functional Requirement of Hinge and gas stay.

• Gap and flushness Requirements.

• Rear visibility criteria.

• Luggage volume.

• Crash Analysis.

• Bend Test, Dent Test, Torsion Test & Endurance Test.

• Rear Crash Regulation.

 PARTS OF BACKDOOR

1.Backdoor Outer Panel:The Outer Panel is the styling surface of the back door.Other components of the backdoor are designed with reference to the outer panel. It acts as the outer cover and deals with the aesthetics of the car.

     outer panel is divided into two parts.

1. Outer Upper Panel:Outer Upper Panel is outermost panel it is join with inner panel by hemming method.the thickness of the outer panel is 0.75mm.there is 0.2 mm gap between the outer panel and inner panel.The relief is also provided at corner of panel 
2. Outer Lower Panel: This panel is also join with the inner panel by hemming method.

   

                        

2.Backdoor Inner Panel:

• Before starting the design of the inner panel of the back door the tooling direction for Deep Drawing purpose should be created.
• The process in which a punch forces a flat sheet metal blank into a die cavity is known as deep drawing. Deep Drawing (DD) is one of the sheet metal forming processes widely used in automobile, aerospace, electronics and allied industries to produce the hollow parts. The improvement in the deep drawing manufacturing process with latest methodologies leads to developments in the automobile and other sheet metal industries.
• Embosses are created on the inner panel for strengthen the panel and When the car hit at rear end, the force which acted should be react outside. The embosses which is helps to move the force to the outer end.
• Thickness of the inner panel is 0.75mm.

3.Hinge Reinforcements (LH & RH):

•  Hinges enable the opening and closing of the back door. One end of the hinge is fixed on the backdoor and the other end on the Roof, on both sides. Hinges can be placed outside or inside the backdoor.
•  The hinge reinforcements are added to compensate for the weak region due to the acting load over it.

4.Gas-Stay Reinforcements (LH & RH): 

• Gas Stay is used for supporting the back door in its open position.
• it requires no manpower and is engaged into support position automatically as the back door opens.
• One end of the Gas Stay is fixed on the backdoor and the other end on the Body Side or on the Back door stationary area.

5.Latch and Striker Reinforcement:

•  The Latch and Striker emboss were designed by creating a trajectory that follows the opening and closing of the back door with respect to the hinge axis.
• The position of the hinge should be perpendicular to the latch when the latch and striker meets. The circle is drawn from the center of the hinge axis to find the path of the striker and positioned perpendicular to the path.

6.Wiper motor Reinforcement:

• Wiper motor reinforcement is created to mount the wiper motor assembly.
• It is small electric motor which is mounted in the rear tail gate. It used to clean the rear wind sheid for clear visibility.

DRAFT ANALYSIS:

Draft analysis is done to show that the Part can be easily drawn out from the mould.

• The draft analysis will be performed for the tooling direction created at first and checked that the model is suitable for manufacturing.
• Then to get a complete green portion the necessary changes to the draft angle of the embosses were carried out by optimizing the model.
• The Draft Analysis command enables us to detect that the part drafted will be easily removed or not.

Outer panel and inner panel relief:

Inner panel with reinforcements: