Design of backdoor

  BACK-DOOR DESIGN

objective:

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

Software used

NX CAD

Backdoor introduction

An automatic back door is the panel that covers the boot of an automobile. it enables access to main luggage compartment. A hinge allows the boot lid to be raised, while devices such as spring or gas cylinders hold it up in the open position. the back door 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 sealent.

Number of parts in back door are:

. bach 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

INNER PANEL DESIGN

TOOL DIRECTION

OUTER PANEL DESIGN

HINGE EMBOSS:

WIPER MOTOR EMBOSS

GAS STAY EMBOSS

LATCH AND STRIKER EMBOSS

WIPER MOTOR EMBOSS

DRAFT ANALYSIS

Draft analysis is done to show that the part can be easily drawn out from the mould.

ASSEMBLY IMAGES

TRAJECTORY

the tragectory is created to position the latch and striker. latch system must be able to catch the striker of the door while closing. circle is drawn from the hinge axis. the striker follow this path.

HEMMING AND RELIEF:

Hemming is the process of joining two suface using set of rollers to bend the parent over the sub part. the brown parent part is the outer panel and other sub part is the inner panel.

Relief is done to increase 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 rollers to pass along smoothly.

HINGE REINFORCEMENT

Hinges support the weight of the whole backdoor.hence,the reinforcement must be provided there too. the emboss is designed in such a way that the hinge should operate freely. the hinge is connected to the rear roof of the car.

GAS STAY REINFORCEMENT

Gas stay reinforcement is used to lift the backdoor automatically. there are two types of gas stay one is semi-automated type the back door needs lift force to lift after that it lift the back door automatically. in fully automated, it has power spindle which lifts the back door automatically.

WIPER MOTOR REINFORCEMENT

Wiper is used to wipeout the rain water falls on the back door window. its actuated by the motor which is mounted on the inner panel. due to the vibration and heat created by the motor. the inner panel where the motor is mounted get deformed and parts attached to the motor starts to vibrate which leads to poor NVH. so we have to provide the reinforcement where the wiper motor is placed.

LATCH REINFORCEMENT

At bottom of the panel, reinforcement and emboss are given to accomodate the latch and striker assembly. generally key operated or automatic remotly controllable mechanism is used to keep the door open or closed. 

FINAL ASSEMBLY

conclusion

thus the back door is designed from the given styling surface and draft analysis is also done on inner panel to check the manufacturing conditions. in this challenge i learned to design the inner panel, outer panel,wiper motor reinforcement, hinge reinforcement, gas stay reinforcement, latch and striker reinforcement and its position.

 LINK

the size of the back door assdembly is greaternthan 20mb so the link of the zip file is attached below.

 https://drive.google.com/file/d/1fgfqwF7ZaWcDepJAsDQYRGR5XWltRVAT/view?usp=sharing