Design of backdoor

BACK DOOR DESIGN USING NX CAD

Introduction:

                Back door or the tailgate is the door for the luggage cabin. This houses the tail lamp and the wipers and may also houses the license plate in some cases. In case the license plate mounted on the backdoor it will also have the license plate lights mounted on it. Backdoor also consists of the inner panel and reinforcements for the gas stay, Latch, viper motor and the Hinges. In case of the rear collision of the vehicle back is responsible for the absorption of maximum amount of force and it needs to dissipate the forces towards the side panels via C-Pillar instead of transmitting it into the passenger cabin.

Design Consideration:

- Rear Visibility

- Hinges and gas stays

- Fit and Clearances

- Boot spaces and accessibility

BackDoor Parts:

• Outer panel
• Inner panel
• Hinge mounting Bracket
• Hinge inner reinforcement
• Wiper motor support bracket
• Latch & Striker reinforcements

Outer panel upper and lower:

                These two panels were referred as the styling part which provides the good aesthetics of the vehicle. It is hemmed with the inner panel. It also holds the tail lamp and Wipers. In some cases, it also holds rear camera which helps for reverse parking.

 

Inner Panel:

Inner panel is the one which provides strength to the outer panel. It holds the reinforcements for gas stay, latch, Hinge, and the wiper motor. Reinforcements were attached to add strength locally and they lose some strength as they are holding some loads. Embosses were made on the inner panel to improve the strength of the panel and dissipates the force away from the passenger cabin. It has the flat surface knows as sealing flange which follows the same line as the rubber part mounted on the roof and side door flange. It will be seating over the rubber part perpendicularly to prevent the water entering the cabin.

INNER PANEL DESIGN:

• EMBOSSING

   

To reduce the weight of Hood, some materials are removed and embosses are created to give stiffness to the panel. Sheet metal embossing is a stamping process for producing raised or sunken designs or relief in sheet metal. In this project the Embosses are created to divide the force towards the hinge joints during collision.

• HEMMING AND RELIEF

Heming is the process of joining two surfaces using set of rollers to bend the parent over the sub part. Here the parent part is the outer panel and sub part is the inner panel.

Relief is done to decrease the stress concentration along the corners and also to decrease the clumping of metal along the corners, this is done by trimming the corner by a minimum radius for the rollers to pass along smoothly.

• DRAFT ANALYSIS

Draft analysis is done to show that the metal can be drawn with the particular design without any tear in the metal of disfiguration. So the above design has been analysed using the tool on NX CAD with having 7 degree as the allowance (All green is good to go).

-Inner Panel:

- Gas Stay Reinforcement:

-Latch&Striker Reinforcement:

-Wiper motor Reinforcement:

-Hinge Reinforcement:

This reinforcement will be manufactured in a two pressing process as the emboss area fails for the single draft.

BACKDOOR ASSEMBLY:

CONCLUSION:

Thus the back door has designed using appropriate methodologies.

Google Drive link:

https://drive.google.com/file/d/14tzRY25hVZur1qmCWIiSDmsyUHxUX6if/view?usp=sharing