Challenge

Design of backdoor

NNarendra Bhalerav9 Oct 2023

BACK-DOOR DESIGN

DUE TO EXTRA SIZE- BACKDOOR ZIP DESIGN FILE UPLOADED IN GOOGLE DRIVE-

https://drive.google.com/file/d/1COaENrlZwXmqCxjlvO7mjrMliae7bkDv/view?usp=sharing

Objective:

Use the provided styling surface to come up with a back door design, use appropriate design methodologies and provide the necessary reinforcements and embosses.

Software Used:
NX CAD

Backdoor Introduction:

An automobile back door or Tailgate is the panel that covers the boot (or trunk) of an automobile. It enables access to the main luggage compartment. A hinge allows the boot lid to be raised, while devices such as springs or gas cylinders hold it up in the open position The Backdoor is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and Reinforcement. Inner panel is attached to the outer panel using mastic sealant.

Total no. of parts in Backdoor are:

Back door outer panel (upper)
Back door outer panel (lower)
Back door inner panel
Hinge reinforcements
Gas stay reinforcements
Latch and striker reinforcements
Wiper motor reinforcements

Embossing:

Embossing is a metal forming process for producing raised or sunken designs or relief in sheet materials by means of matched male and female roller dies, theoretically with no change in metal thickness or by-passing sheet or a strip of metal between rolls of the desired pattern. Metal sheet is drawn through the male and female roller dies producing a pattern or design on the metal sheet. Depending on the roller dies used, different patterns can be produced on the metal sheet.

Materials commonly used in the metal embossing process include:

Aluminum alloys
Steel alloys
Zinc
Copper
Galvanized steel
Brass
Cold rolled steel

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.

In car part production, hemming is used in assembly as a secondary operation after deep drawing, trimming and flanging operations to join two sheet metal parts (outer and inner) together. Typical parts for this type of assembly are hoods, doors, trunk lids and fenders.

There are various types of hemming operations:

Conventional die hemming: In conventional die hemming, the flange is folded over the entire length with a hemming tool.
Roll hemming: In roll hemming, the hemming roller is guided by an industrial robot to form the flange.

Given surfaces has to be repaired according to the smoothness. After repairing the surfaces, the door is divided into two parts as Door Outer Upper and Doo Lower Panel.

INNER PANEL DESIGN: