Design of backdoor
AUTOMOTIVE DESIGN OF CAR BACK DOOR USING NX CAD
OBJECTIVE:
- I) From the given styling surface, develop a back door using appropriate design methodologies.
- II) The objective of this project is to design a BIW Back Door of a car with an Inner Panel, Outer Panel, and Reinforcements for the Hinges, Gas stay, Wiper Motor, and Latch by following the engineering standards.
III) The Inner Panel must be subjected to Draft Analysis for verifying whether satisfies the Deep Drawing requirements for the tooling direction created in the design.
SOFTWARE USED: Siemens NX CAD
INTRODUCTION: The Back Door of a car is the rearmost part of the vehicle which gives access to trunk space of the vehicle. The rear door also supports the reinforcements and add weights of the Wiper Motor, Gas Stay, Tail Lamp, and Latch and Striker.
The Backdoor/tailgate is one of the closure commodities in BIW sheet metal design The backdoor has a lot of components inside and is designed to incorporate them easily. affects the rear visibility and luggage area.
The material used for door manufacturing depends on the budget and performance of the vehicle. Mostly Aluminium and Steel will be used whereas low-budget vehicles us Steel which makes the manufacturing process easy and cost-efficient since it follows the Stamping of Moulds.
Major Parts and Reinforcements:
The backdoor consists of the following basic components:
- Backdoor Outer Panel (Upper)
- Backdoor Outer Panel (Lower)
- Backdoor Inner Panel
- Hinge Reinforcements (LH & RH)
- Gas-Stay Reinforcements (LH & RH)
- Latch and Striker Reinforcement
- Wiper motor Reinforcement
TAILGATE:
Tailgate is a door at the back of a truck or car, that is hinged at the bottom so that it opens downwards.
DESIGN INTENT
The intent of the project is to design a Body In White Back Door of the vehicle considering the engineering standards and manufacturing requirements which satisfies the Deep Drawing Process.
DESIGN CONSIDERATION OF A BACKDOOR:
Functional Requirement of Hinge and gas stay Rear visibility criteria Luggage volume Crash Analysis Bend Test, Dent Test, Torsion Test & Endurance Test Rear Crash Regulation Gap and flushness Requirements.
DESIGN OF BACKDOOR OUTER PANEL:
The Outer Panel is the styling surface of the back door. Other components of the backdoor are designed with reference to the outer panel. It acts as the outer cover and deals with the aesthetics of the car. In this design outer panel is divided into two parts
- Outer Upper Panel
- Outer Lower Panel
Outer Upper Panel:
The Outer Upper Panel Extracted from a styling surface. The panel is altered for the required design with the surface tools of NX CAD The thickness provided for the outer panel is 0.75 mm Hemming is provided with the corner relief.
Outer Lower Panel:
The Outer Upper Panel Extracted from a styling surface. The panel is altered for the required design with the surface tools of NX CAD The thickness provided for the outer panel is 0.75 mm Hemming is provided with the corner relief.
Backdoor Inner Panel:
Inner panel will add reinforcement and make rear door to withstand the load and forceses acting, inner panel will have the emboss and will provide housing.Emboss are made to make stonger and pass the air through when driving.
MASTIC SEALANT:
The mastic sealant is used to fix the inner panel with the outer panel which increases the NVH factor and stiffness of the back door.
HINGE, GAS STAY & WIPER MOTOR EMBOSS:
The Orange circle denotes the hinge emboss which was created using the datum plane and emboss feature in NX. It was also designed in a way that the emboss should have a flat surface for assembling the hinges using it. The violet circle denotes the gas stay emboss which was created using the surface of the connecting flange.
LATCH AND STRIKER EMBOSS: The Latch and Striker emboss were designed by creating a trajectory that follow the opening and closing of the back door with respect to the hinge axis.
STRIKER POSITION: The position of the hinge should be perpendicular to the latch when the latch and striker meets. The circle is drawn from the center of the hinge axis to find the path of the striker and positioned perpendicular to the path.
HEMMING: Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming is the process in which the edge is rolled flush to itself
The outer panel was designed as two separate parts named as outer panel upper and outer panel lower. After designing the outer panel, the Hemming was created by offsetting the surface with the help of face blend and swept surface. The two separate outer panels will be joined using Blanking.
Hinge reinforcement:
Hinges enable the opening and closing of the back door. One end of the hinge fixed on the backdoor and the other end on the Roof, on both sides. Hinges can be place outside or inside the backdoor. The hinge reinforcements are added to compensate for the weak region due t the acting load over it.
Gas Stay Reinforcement:
Gas Stay is a device used for supporting the back door in its open position. Gas stay requires no manpower and is engaged into support position automatically as the bac door opens. One end of the Gas Stay is fixed on the backdoor and the other end on the Body Side or on the Back door stationary area. Embossing is provided at the Gas Stay mounting area to compensate for weakness and improve strength.
Wiper Motor Reinforcement: Wiper motor reinforcement is created to mount the wiper motor assembly
Latch and Striker Reinforcement: The Latch & Striker forms the locking mechanism of the backdoor with the car. Du to regular opening, closing, and over slamming of the backdoor, there is stress developed in the Latch and Striker area. To compensate for the same, reinforcements are added i this area.
DRAFT ANALYSIS:
The draft analysis will be performed for the tooling direction created at first and checked that the model is suitable for manufacturing. Then to get a complete green portion the necessary changes to the draft angle of the embosses were carried out by optimizing the model.The Draft Analysis command enables us to detect that the part drafted will be easily removed or not. This type of analysis is performed based on colour ranges identifying zones on the analysed element where the deviation from the draft direction at any point, corresponds to specified values.
Material Used for rear hood:
Basically, aluminium and steel are used for the hood.
But there is advantage and disadvantages of these two materials. Please see the below image.
Load Case on Rear Hood:
Below load tests on done on the rear hood, this is done after the work of styling team.
CONCLUSION:
Thus, the Body in White Back Door of a car was designed following the engineering standards and also the deep drawing requirements were satisfied.