Design of backdoor
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 it satisfies the Deep Drawing requirements for the tooling direction created in the design.
INTRODUCTION:
The Back Door of a car is the rearmost part of the vehicle which gives access to the trunk space of the vehicle. The rear door also supports the reinforcements and added weights of the Wiper Motor, Gas Stay, Tail Lamp, and Latch and Striker.
Major Parts and Reinforcements:
The backdoor consists of the following basic components:
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Backdoor Outer Panel (Upper)
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Backdoor Outer Panel (Lower)
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Backdoor Inner Panel
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Hinge Reinforcements (LH & RH)
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Gas-Stay Reinforcements (LH & RH)
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Latch and Striker Reinforcement
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Wiper motor Reinforcement
Deign of inner panel :
Here i attached the the design of the inner panel with reinforcement of hinges RH&LH,Gas stay reinforcement RH&LH
Latch reinforcement wiper motor reinforcement .The image is attached below .
The green color on the top of the inner panel denotes the reinfocement of hinges .
the rose color which denotes the reinforcement of gas stay which placed right and left side of the inner panel .
The default color in the inner panel denotes the wiper motor reinforcement in the top most middle of the inner panel .
In the bottom of the inner panel with default color denotes the latch and striker reinforcement .
Hinge reinforcement :
The attached images the reinforcement of the hinges for both right and left side on the top
Gas stay reinforcement :
the above shows about the reinforcement of the gast stay which palced in both right side and left side of the inner panel
wiper motor reinforcement :
The above image shows that the reinforcement of the wiper motor .
Latch and striker reinforcement :
the above images shows that the reinforcement of the latch and striker reinforcement which is palced in the bottom of the inner panel .
Design consideration of back door :
the main aim of designing the back door is to increase the strength of the back door and also provide the luggage space for the door .
to increase the strength of the inner panel by creating the emboss on the inner panel which showned below .
The above image reffered to the inner panel with emboss .
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
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Outer Upper Panel
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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.
Tooling direction :
The styled surface is to check with analsyis of the draft for to fix the irregularities of the design .
the tooling direction the images is attached below .Then the back door was designed using the top-down approach.
on based on the above images the inner panel is statisfied with the draft analysis .
Hem relief :
after the hemimg process we should provide the hem relief for the puter panel to reduce the stress in the inner panel .The image of the hem relief is attached below .
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 thickness of the inner panel is about the 0.75 mm thickness towards the the outer panel and thickness of the outer panel is about 0.75 mm thickness the tolerance value between 0.2 mm .the total thickness is about 2.65mm .the image of the hemming is shown below
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.The images which is attached below .
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.
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.
I am not able submit my document so as per guidance i have attched the my submitting document link .please see below . https://drive.google.com/file/d/1YCkgA_MpqbODOA0DaqQm42oBZC2YTiwn/view?usp=sharing