Design of backdoor

 CAR BACK DOOR DESIGN

Aim: To design back door of car using given outer class 'A' surface.

What is back door of a car?

A door which is located at the rear side of a car which gives access for the boot space to store luggage, spare wheel etc.

These doors can be operated manually or electric powered. In most of the luxury cars door is electrically operated.

Different Sheetmetal processes used for manufacturing the Back Door

Deep Drawing:

Embossing:

Hemming:

Blanking:

Punching:

Design of Back door in NX CAD: 

Door parts thickness is given below,

1. Outer Panel - 0.75 mm
2. Inner Panel - 0.75 mm
3. Reinforcements - 1.5 mm

Given Data,

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.

First, we need to create the Tooling direction for the Deep drawing operation. It shows that all the operations like embossing is done by considering this vector direction and it will help in manufacturing the part,

After that we have to create Sealing Flange by offsetting the outer panel to the specific distance.

Then we will be creating the Back door inner panel flange by offsetting the outer surface at a distance considering the sheet thickness and thickening direction.

Then created the connecting flange to join the inner panel and sealing flange.

Then for the windshield panel mounting, windshield panel is created and joined with sealing flange.

Then to improve the strength of the inner panel and to reduce the weight 'Y' type emboss and other cut-outs are created. Also, for Latch and Stricker mounting cut-out is created. This cut-out is also done on other side of the inner panel to maintain the centre of gravity of the Back door.

Another Emboss is created for Wiper motor mounting.

Another flange is created to reduce the vibration of door by joining the inner and outer panel with the help of Mastic sealant.

Now to assemble the back door with the vehicle Hinges are used to open and close the door. For that to increase the local area strength we have to design the emboss and provide the appropriate reinforcements to withstand the load acting upon it.

For positioning the Latch & Stricker, we have to create a trajectory passing through a midpoint of line/ axis of two hinge mounting holes,

Latch & Stricker Emboss,

Gas Stay Emboss and Reinforcement,

Hemming and Hem Relief,

Assembly: