Design of backdoor

                                       Design of Back door 

        Objective :

            To Develope the Car Back Door by using given Styling Method by Automotive 

        Sheet metal design.

        Introduction :                                                                                                                                   

            Design of back door is also called as the Tail gate. A car back door which is consist of Inner 

        panel Outer panel. Basically the car parts are made of Steel or Aluminium based on the budget of 

        the car.     

        Using Aluminium improve the Strength where we can avoid the reinforcement. Aluminium parts are

        casted and we can very the thickness of the part, because of this avoid or reduce the number of 

        parts as compared to Steel. Only drawback is the cost of aluminium, which is high cast as 

        compared to steel.                                                                                                                                                                                

        Steel parts are stamped, we cannot vary the thickness of the part because of more number of 

        parts are added. Which could increase the weight of the part.                                                         

        So now a days most of the car manufacturers are trying to use Aluminium instead of Steel and 

        they reduce the number of parts and weight of the car drastically.

                                                          Steel                                           Aluminium       

        Parts                                    parts are stamped                             parts are casted      

        Reinforcement                      Necessary                                         Can be neglected

        Thickness                             Constant                                           Can be varied

        Components                         More                                                 Less in number

        Weight                                 More                                                 Lighter

        Cost                                    Less in Cast As compared to all            More as compared to Steel

        Components of thr Back Door :

        Outer panel upper

        Outer panel Lower

        Inner panel 

        Latch and Strike Reinforcement 

        Hinge Reinforcement 

        Gas stay Reinforcement

        Wiper motor Reinforcement

        Design considerationfor a back door :  

        Rear Visibility 

        Boot space and accessibility 

        Fit and Clearance 

        Support Structureslike hinge and gas stays

        Mount for wiper motor, tail lamps, and other wiring loops.

        Inner panel :

                 Emboss:                                                                                                                                  

       Sheet metal embossing is a stamping process for producting raised or sunken designed or relief 

       in sheet metal. This process can be made by means of matched male and female roller dies or 

       by passing sheet or a strip of metal between rolls of the desired pattern.

                       Embossing is done by pressing a sheet of par=per in to female die, that has a design 

       etched into it. This is usually done with a male counter part underneath the paper so that the 

       two and the design is transferred to the paper.

       Force Distribution :

       When the car hit at rear end, the force which acted should be react outside. The Y/V emboss 

       which is helps to move the force to the outer end.                                                                  

       

      Hinge Reinforcement : 

           Hinges are the essential, that allows doors to pivot on one edged as open they open and close.

     They are found on virtually all doors. It is an mechanical bearing that connects two solid objects, 

     typically allowing only a limited angles of rotation between tehm.

     

     Gas stay Reinforcement :

      

      They are two types of Gas stay reinforcement is there. That they are 

      Manual System

      Power lift System 

      Manual System : 

      This mechanism is most used in india cars. It is operated man by his ow.

      Power Lift System : 

      It works on the basics of Sensor.

      Latch and strike Reinforcement : 

      

      Latch placement :

      Using the axis of the hinge, a circle is drawn at the middle of the back door and the latch is placed

      perpendicular to the circle. 

      

      Wiper motor reinforcement : 

      It is small electric motor which is mounted in the rear tail gate. It used to clean the rear wind sheid 

      for clear visibility.                                                                                                                                     

      

      All reinforcement mounting points :                                                                                                

      

      Outer panel :

      Outer upper panel:

       

       Outer inner panel :

       

       Hemming :

       Hemming is a forming operation in which the edges of the sheet are olded or folded over another 

       part in order to achieve a tight fit. Normally hemming operations are used to connect parts 

       together, to improve the appearance of a part and to reinforce part edges.                                         

       Hemming is used in assembly as a secondary opreration after deep drawing, trimming and 

       flanging operation to join two sheet metal parts (outer and inner) together.

                                                                                                                                                               The accuracy of the hemming operation is very important since it affects the appearance of the 

       surface and surface quality

                  Hear hemming thickness- 1mm

      

      Corner Relief : 

      Relief helps to control sheet metal material behavior and to prevent unwanted deformation during

      unbend operations. So here i gave two corner relief for back door.                                                        

                

      Back Door Assembly :                                                                                                

                

      Conclusion :

      The design of the Back door BIW was completed with the engineering standard and all the 

      reinforcement.