Design of backdoor
1) In this challenge, we have to design the back door as per given given dimensdion
Components of the Back Door :
Outer panel upper
Outer panel Lower
Inner panel
Latch and Striker Reinforcement
Hinge Reinforcement
Gas stay Reinforcement
Wiper motor reinforcement
Design consideration for a back door :
Rear Visibility
Boot Space and accessibility
Fit and Clearance
Support Structures like hinge and gas stays
Mounts for wiper motor, tail lamps, and other wiring loops.
Inner panel :
outer pannel upper part
outer pannel lower part
assemble of all part
Emboss:
Sheet metal embossing is a stamping process for producing raised or sunken design 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 as they open and close. They are found on virtually all doors. It is a mechanical bearing that connects two solid objects, typically allowing only a limited angle of rotation between them.
Gas stay reinforcement:
It is used to lift up the Tail gate.
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 own.
Power Lift System :
It works on the basics of Sensor.
Latch and striker 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 folded 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 operation 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.