Design of backdoor

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

BACK DOOR - The back door, also known as a "tailgate," serves as an entry and exit point for a vehicle, providing access to the luggage compartment. Often operated by gas stays, it reduces effort in lifting. Luxurious cars may have electrically powered back doors, known as a power trunk lid system. Hatchback or station wagons are sold as 3 or 5-door models, with the rear hatch classified as a door. A back door typically consists of seven main parts.

TYPES OF BACK DOOR ACCORDING TO THEIR WORKING POSITION -

1. Top mounted - This type of back door is used in a station wagon, pickup truck, and some of the sport utility vehicles.

2. Side mounted - Side-mounted doors are mounted on the side of the car. Vans, SUVs, MPVs, and Trucks use this type of back door.

3. Bottom type - This bottom-type backdoor system are used in car types such as car, pickup truck, and some luxury SUVs. These are the most convenient type of back doors in which the bottom split is used as a support or even as a table for tour-going people.

COMPONENTS OF BACK DOOR -

1. Outer panel - The outer panel is the outermost surface of the back door which is more focused on outer appearance and aestheticness. for making this we have given class A surface at the beginning of the project.
2. Inner panel - The inner panel is made to improve the strength of the overall back door and its purpose is more strength-oriented.
3. Embosses -Embosses are created to make the sheet metal more strong and rigid to decrease the flexibility of the material. And provide a more rigid strength
4. Gas Stay - Gas stay is the mechanism used to provide movement and extra force to open and close the back door it also prevents the door from sudden collision from its open state.
5. Gasstay reinforcements- Gasstay reinforcements are the extra reinforcements to add more strength to the joining point of gas stay in the back door to make the metal layer more strong in that place.
6. Wiper motor reinforcements - wiper motor reinforcements are added to make extra support for wiper motor mechanisms.
7. Hinge and latch mechanism- The hinge and latch mechanism is made for the ease of opening and closing on a fixed trajectory.
8. Hinge reinforcements - Hinge reinforcements are made to improve hinge strength where the hinge is mounted.

The material used to make a back door -

The common materials used are Steel and aluminum. The density of Steel is higher than Aluminum thus adding more weight to the door. The material used in the manufacturing of the backdoor depends upon the budget of the car, most low-cost vehicles use steel as it is cheaper compared to Aluminium.

Design considerations -

• Rear visibility
• Boot space & accessibility
• Sealing Flange
• Support structures like hinges and gas stays.
• Mounts for wiper motor, tail lamps, and other wiring loops
• Rear crash regulations
• Joining techniques such as hemming, spot welding, etc.
• Gap and flush requirements

Completed door panel -

Draft analysis -

Conclusion - So by following support videos and my previous learning I developed this door panel with all required reinforcements.

google drive link - https://drive.google.com/file/d/1ZPiMIQQnvWnaO1_-Qc7EBBWR1dbwieho/view?usp=sharing