BACK DOOR/TAIL GATE DESIGN

Objective :

to develope a back door from the given class-A surface with outer panel, inner panel and required reinforcements with proper draft angle by following the design paramaters.

INTRODUCTION

the back door of a car is a importent component in the overall design and functionality ofthr vechicle. beyond its basic function of providing access to the rear compartment, the back door contributes significantly to the safety, convinence and asthetic appeal of the entire automobile.

INPUT ( CLASS-A )

Here is the given class A surface from which we need design the other componets of the back door

TYPES OF BACK DOOR MOUNTING

• top mounted door
• bottom mounted door
• side mounted door

here we are designing a top mounted back door / tail gate which we will have the mounting hinges on top 2 sides of the door which will be mounted sides of the roof

COMPONENTS OF BACK DOOR

• Outer panel (upper & lower)
• Inner panel
• Hinge mtg reinforcement (LH & RH)
• Gas stay mtg reinforcement (LH & RH)
• Wiper motor mtg reinforcement
• Latch mtg reinforcement

OUTER PANEL

as the name suggest it the external surface of the back door which encases the structrual components of the door and serve as a both a protective barrier and an asthetic feature. it shields the internal components of the door while controbute the overall appreance of the vechicle.

in this given design we have the outer panel as two portion one upper and lower portion. and each have a 0.75 mm thickness.

• Outer panel upper

• outer panel lower

INNER PANEL

The inner panel of the back door is the interior surface which faces the vechicle's cabin it provides structrual support and house svarious components such as door handle, latch mechanism, speakers, rear viper motor and wiring's etc.

our back door inner panel is in a single piece design with required emboos and cutouts and the inner panel is designed with proper draft angle which minimum of 7degree and with thuickness of 0.75mm

and we have provides emboss in Y/V shapes so if a crash has occured the force will be distributed to the sides of the car which will reduce the damage for both the car and passengers inside.

we have provided cutouts in areas where posible which will help to reduce the over all weight of the back door. which will contribute in the over all perfomance of the vechcle.

we have give give support between the outer panel and inner panel at 3 places rather then the edges, which will give extra strength for the outer panel.

REINFORCEMENTS

We give reinforcements at areas where we have mounting points. to give extra strenght for the mountng and to overcome the lose of strength due to the mounting holes provided on the panel.

we have provided the reinforcement panel with 1.5 mm thickness

1. HINGE MOUNTING REINFORCEMENT

as the name suggest its a local area reinforcemnt at the LH & RH sides at top of inner panel where the hinge will be mounted. these reinfocement we balance the loss in strength due to mounting of the hinge

2. GAS STAY MOUNTING REINFORCEMENT

the gas stay is mounted at 2 points one side at the car body side and the other side at the back door. we have provided the reinforcement at the 2 sides of the inner panel of back door.

3. WIPER MOTOR MOUNTING MOUNTING REINFORCEMENT

the high end varients cars will have wiper blades on the rear windshield also. so the rear wiper motor should mound on the back door, for that we give extra reinforcement att the center of the inner panel

4. LATCH MOUNTING MOUNTING REINFORCEMENT

normally the latch or striker will mounted on the bottom side of the tail gate for top mounted tail gate. so we provided reinforcement for that also.

• LATCH PLACEMENT

for palcing the latch and stricker perpendicular to ech other. we draw a circle with the center as the axis of hinge and passing through te center of latch and stricker

and we place the latch parallel to the circle.

HEMMING

hemming operation will help us to get a reinforced edge, a good asthetic in appearance and a better connection between the panles.

process:- roll heming id carried out incrementally witha hemming roller. an industrial robot guides the hemming roller and forms the flange. roll hemming opertaion can also be divided into several pre-hemmig and final hemming process steps

hemming process

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i have provided relief at corners for a easy memming process with with out effect the asthetic of the door panels.

TOOLING DIRECTION

The inner panle normaly produce by castig or deep drawn, casting is normaly done foe aluminium. here we use steel as the raw material so we use deep drawn method so we need a tooling direction with a minimum of 7 degree draft angle.

and we created the tooling direction with minimum of 7 degree draft angle and we also have done draft analysis with that tooling direction.

DRAFT ANALYSIS

Our draft analysis is successful with the minimum draft angle of 7 degree, exepect the supportin area between the inner and outer panle which is not a big problem. because that part wont be in the deep deawing process it will be seperately after the deep drawn operation with a punching operation.

note: sir, i have tried to upload the zip file of my project in the project page but its zise was more then 20 mp.

so i have send you the google drive link in this mail - [ [email protected] ]

[ i was having a exam and a project on going , and i was not able to continue the back door project for 3 months and i dont want to rush the course by not studying properly. that is why i was late to submit the project.]