Design of backdoor

Design of back door Assembly

Objective

The aim of this project is to  best design a backdoor assembly with inner panel by using the provided styling surface to come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcements and embosses.

Design Procedure

• Initially the back door outer upper and lower panels are given as input part. Here we take the top down approach to assemble the component and so we open an assembly file and the outer upper and lower panel.
• Before this we open the input part file sperately and ensure all the surfaces are scott free and make corrections if needed to get a smooth surface.Then wec reate new parfiles and copy the upper and lower outer panels seperately as different part files.
• Now we bring in those seperate outer part files into teh assembly file and fix them(constraint.).
• Now we create inner panel inside the asm file and use the WAVE geometry linker to bring in the outer panel parts into the innerpanel part of the same assembly.
• This becomes reference geometry.We extract the same and it "feature group" them as the working surface.
• We offset both thes working surfaces by 1.7mm downward and these two surfaces are the inner panel. We extract these surfaces and use them for further creation so that when we need.
• Next,we move on to sealing flange creation.This is created way below the outer panel and with a minimum of 12-15mm offset from the sides.
• Later the edge of the sealing flange is used to create a law extension with draft to pierce the innerpanel extracted body-upper.Similarly lower too.
• The gap between the upper and lower innerpanel surfaces are filled and sewn togehter.Next the windshield was created according to the help video.
• Now it is neccessary to create the mountings for the reinforcements.Hinge, gas stay,wiper motor and latch/striker mechanism. To do this we create a surface below the region where we need it (curved region) and extrude a line to form the surface.Then law extension from its edges on to the innerpanel and we use trim and extend to create it. 
• Then blends are given and made sure they become part of the inner panel.In this way the all the other moutings are also given with holes.
• Now embosses are given to increase strength and to divert imapct force.Also reliefs are given whereever needed to reduce stress concentration factors..This part is then mirrored on the oter side and sewn togehter as the complete inner panel.