Design of backdoor

Back Door Project

Design Consideration:

1. Sealing Flanges -To Protect the water & Dust entry from outside and Sealing flanges will push the robber seals during closed condition.

2. Create mastic points between outer and inner panel to avoid vibration and strength.

3. Luckage area space consideration while creating Sealing Flanges.

4.Latch and striker trajectory point for smooth door opening and closing of bak door.

5.Gas stay, hinge,striker mounting reinforcement to enhace the strenth locally.

6. Emboss creation for distribute the impact Force during collision towards out side of the car to save the passenger

7. Rear light arrangement to be privided for Installation.

8.Viber Motoe Mounting to Be consider.

Project Execution:

Get the Backdoor Upper and Lower skin data ,and Check the Surface to be joined neatly .If not repair it.

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Given Skin Data lot of has lot of issues and gaps . Its repaired for further reference for Creating Inner Panel and Reinforcements for creating strength Locally. Back door Upper and Lower to be spot welded since it required 8mm space Arrangements required.

Inner Panel:

Take Reference from Outer panel Upper and Outer Panel Lower .Now as per the benchmarking data sealing flanges width required minimum 20 mm. so Considering these data planned for flanges wide 25mm for Blending surface as well.Once if we creating the Flange width give flange depth to be consider Luckage Space As well.

Mastic Points to be provided to joint Outer and Inner Panel. then Emboss to be Provided to disipate the crash requirments. Emboss to be projected towards the outer side to absorb the collision. it helps to redution the Door Weight considerably.

Hinge and Gas stay Mounting to be prepared as per the bench marking requirements. Diatance between Hinge Axis and Gas stay should be 80 mm . and Mounting should be Flat surface to Bolt the hinges and Gas stay.

Hinge Axis to be Prepared and Door closing and opening trejectory line to be followed with respect to the Hinge Center Line.

Striker lock should be tanget the to the Trajectory Line for smooth Open and Closing. if Not maintaining it will be difficult to customer open and close the door.

If Striker Location Identified Monting Arrangement to be prepared and Check to Thicken the surface by towards upward directed as per Hemming and Mastic glue requirments.

Reinforcement :

Reinforcement bascially helps to create the strength locally where we have mounting the additional parts.

its give more more syrenth during collision and moving Condition.

Hemming:

Hemming is the process to join the sheet metal patrs where we cant do welding and asthetical condition. Hemming will be done by roller in different levlel to bend it not to come thier spring back effoct. .2 mm gap to be maintained for apply hemming glue it will spread and hold the upper and Lower Sheets .

Final Door Assembly Design: