Design of backdoor
INTRODUCTION:
The Trunk (North American English) and Boot (British English) of the car is the vehicles main storage component, often a hatch of the component of the vehicle. This doors can operate manually or electric power.
It involves very major role during rear crashes, so or design must be obey crash requirements, the institute of highway safety analyse the different accident and they set a rate of our car. This ratings depends upon the design of the trunk, material used, flanges, embosses, types of joining of inner and outer panel etc.
TYPES OF DOOR BASED ON WORKING POSITION:
1. Top Mounted Door
2. Side Mounted Door
3. Rear Door
FUNCTIONS OF THE BACK DOOR:
It Protects the occupants and luggage from getting damage
It houses assembly of tail lumps, wiper motor and other components.
It serves as entry and exit point of luggage/ passengers.
It houses wind shield glass which helps rear visibility parking sensors, rear view camera monted on it.
1. Electrically Operated:
2. Gas Stay Powered
The Main purpose of these mechanisms is to open the backdoor without effects, because the back door has different parts, and weight of the backdoor is high, so we are not able to open the back door manually, so we introduced these two types of mechanisms, they operates electrically and used to open the back door.
BACK DOOR ASSEMBLY:
Inner Panel
Outer Panel
Hinge and its reinforcement
Wiper motor reinforcement
Latch & sticker and its reinforcement
Gas stay reinforcement
MANUFACTURING PROCESS:
It Assemblies made from stamped metal panels welded together to form a tragile. Latches are added in either side of the tailgate to engage the sticker on the pickup sides. A Handle operates the latches to open and close the tailgate assembly. Steel tailgates assembly provides a durable and secure closure for a pickup load.
Another disadvantage of steel tailgate assemblies is the cost of the tooling required and equipment required to stamp metal tailgate components. Metal tailgate components are generally produced in a large stamping press. The stamping presses generally require finely machined tools made from hardened steel. The cost of tooling a metal tailgate is much more expensive.
PROCEDURE:
1. Checking the Geometry
Once the model is opened, we get a class A surface of a back door.
2. Tooling axis creation
Draw a line from left and right extremes almost parallel to the path of the surfaces along the unsymmetrical axis.
Used a derived line tool, create the bisecting lines as shown below.
7. DRAFT ANALYSIS:
1. Inner Panel:
Gas Stay Reinforcement
Gas Stay support the weight of the back door while they are open. More load act at the region suituable reinforcement provided for better strength.
Wiper Motor Reinforcement
It provides in this region for fixing the wiper motor.
Latch and Sticker Reinforcement:
The Sticker is designed to create a tight fit between the door and the seal on the cab. The door open and shut the several times in a day. More force acting on this area. The reinforcement given the latch and sticker mounting area to increase the strength. It is spot welded on the inner panel.
Trajectory:
It is created the position the latch and sticker. Latch system must be able to catch the sticker of the door while closing. Circle is drawn from the hinge axis.
Hemming:
It is the technology used by the automotive industry to join inner and outer closer panel together. In addition bonding provides for excellent joining of panel. It also reduces the vibration. Here this design 0.2mm clearance provided for hem glue.