Design of backdoor

AIM :Use the provided styling surface to come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcements and embosses.

BEFORE STRATING THR DESIGN WE SHOULD KNOW THE DESIGN CONSIDERATION FOR THE BACK DOOR:

1. THE REAR VISIBILITY :

 The design should be such that the no intereferance should come in the visibity of rear of the vehicle. The that have been left for the back door glass ,should be left undisturebed.

2. TRAJECTORY AND OPENING ANGLE: The trajectory of the door should be checked carefully and it should be made sure that the hinge axis of both should be colinear.

3. POSITION OF GAS STAY HINGE: Depending upon the angle of opening and the length of the gas stay , the hinge should be properly placed so that the opening and closing can be done seamlessly. 

4.REINFORCEMENT : All places where some load is going to be applied such as hinges,wiper mounting etc . at those places proper thickness reinforcment pad should be applied.

5.NECESSARY CUTOUT: Proper cutout should be given for the access tail lamp mouning area, wiper mounting area, registration plate light area, latch mounting area , thease areas should easily accessible.

6.MAXIMISING BOOT SPACE : It is always recomeneded for a designer to keep in mind to have aximum possible trunk space by avoiding uneccessary bulges the inner panel of the back door.

7. MASTIC FLANGE :

   For mastic flange two things need to be considered first that proper clearance should be provided for application of the mastic ,the surfaces should follow the outer panel profile,second thing is the length of the mastic flange ,the length of the mastic flange shoud be enough to reach the mastic clearnace at the same time it should not lengthier than the cutout length from the parent metal. 

THE PROCESS WHICH IS FOLLOWEDTO MAKE THAT FLANGE IS CALLED LANCING OPERATION.THE VARIOUS STEP THAT I HAVE SHOWN THERE IS NOT POSSIBLE IN THAT.

8. DECISION FOR LOCATION OF MASTIC,HEMMING AND SPOT WELDING: The flange between the outer panel and the inner panel at the center which is created by lancing operation is choosen to be attached by mastic as it is comming in contact with the class A surface. 

The second joining methode being employed is the hemming operation which needed to be done along the peripheral boundry of the backdoor.

The third joining operation is the spot welding operation which is going to be employed between the upper outer panel and the lower outer panel.

The deep drawing method and and the hemming method and types has already been discussed in previous challenges.

Draft analysis:

the draft analysis comes to correct except at some location as mentioned below.

The parts the upper outer panel and the lower outer panel are going to be manufactured separately so we can adjust the tooling axis separately for each of them to tackle the drraft problem.

This shows yellow colour which can be corrected by slightly canging the angle as it exact 7 degree.

All monting areas has been provided with reinforcement pad.