Design of backdoor

BACK DOOR DESIGN:

OBJECTIVE:

To design the back door of the car with using of given styling surface from the styling team,and design inner pannel and outer panel of the back door with reinforcement.

INTRODUCTION:

The trunk (North American English) or boot (British English) of a car is the vehicle's main storage or cargo compartment, often a hatch at the rear of the vehicle. It is also called a tailgate.mainly it is used for storage area door and give area for back side.It contains gas stay mechanism for openning and closing the door,some cars had power module servo motors for closing and opening the back door,example in tesla,MG like electric premium cars had this kind of feature.

when we are going to design the backdoor we need to consider safety creteria,for that we need to increase the strength then only we acheive the crash test safty creteria for that we need to provide the reinforcement

then we need to consider latch and stricker point,and GD&T things like perpendicularity between latch and stricker position. 

BACK DOOR ASSEMBLY PARTS:

1.INNER PANNEL

2.OUTER PANNEL

3.HINGE REINFORCEMENT

4.LATCH AND STRICKER REINFORCEMENT

5.WIPER MOTOR AREA

6.GAS STAY REINFORCEMENT

MATERIAL SELECTION FOR BACK DOOR:

In olden days we are mostly used steel for manufacturing the car automobile bodies but it had high cost and high in weight.Manufacturing time and cost also high when compare to current manufacturing methode using aluminum.When compare to steel,aluminum had lot of advantages,as we mentioned below,

here,we saw the top end cars of the world in current market are using aluminium and steel material for car back door,

 above mentioned table tells about the material usage in back door of the car,the steel and aluminium material are used because it is lesser in weight and cost to produce the automotive parts.

from above mentioned flow chart we find out the assembly sequence of back door,and from above mentioned pie chart we find the usage of aluminum blank and aluminium cast.

after assebling the part we have to do above mentioned endurance test for test the stregth of the back door.

here some embosses for using divert the force around the back door equally.its give better strength for back door.

TYPES OF SHEET METAL OPERATIONS:

1.SHEARING OPERATION:

Shearing operation is used for cut or shearing the sheet metal,or blank.In this operation the work piece hold by upper and lower holding die and blade will cut the metal.

BLANKING OPERATION:

Blanking is the operation thats bend or cut the sheet metal with in the die.for this operation we had uesd punch and die.

PUNCHING OPERATION:

Punching and blanking had same operation,but by punching operation only we got the blank condition of the sheet metal.

PIERCING OPERATION:

By piercing operation we got the required shape of cut by puncing on the sheet metal.

TRIMMING OPERATION:

Trimming operation is used for cut the edges and unwanted burrs from the blanked sheet metal.

DRAWING OPERATION:

This process is used for creating thin and deep hallowed parts,by punch and work holding dies.it had two methods that are

1.deep drawing:depth is greater than the breadth.

2.shallow drawing:length is lesser than width.

EMBOSSING OPERATIONS:

It is used when profiles need on sheet metal,it gives strength to the sheet metal when loads are acting on the profile.

BENDING OPERATIONS:

Above mentioned fig tells about all types of bending operations on sheet metal.

SQUEEZING OPERATION:

It is the process that squeeze the metal to form the material to required shapes using die and punch.It had two methods that,

sizing:In sizing methode we got any required shape which die allows the material.

coining: it is process that to get the round shapes by squeezing the metal,like coin,medal and etc...

DESIGN MODEL FOR BACK DOOR:

Here I am using solidworks and NX for doing model with given styling surface.giving embosses and strength to inner panel.reinforcement,mounting hole region,lacer stricker area and motor mountung area also provide in inner pannel.

OUTER PANEL:  

INNER PANEL:

EMBOSSES:

MOTOR MOUNTING AREA:

LACER AND STICKER AREA:

MOUNTING AREA :

DRAFT ANALYSIS:

CONCLUSION:

From this challenge we understand how to design the back door with types of materials used in back door manufacturing,safty measures,types of sheet metal process involved in sheet metal manufacturing,and strengthening the back door,finally over all challenge was very informative and good.