Design of backdoor
Backdoor Design
Backdoor is an important component of the vehicle. Besides acting as a door, it functions other purposes like, it have the glass which is required for the visibility, contain the rear lambs for many vehicles etc. So while designing the backdoor, a lot of things have to be taken into considerations like glass area, wiper mouting, rear lamp mounting, latch and striker mechanism mounting, number plate and lamp mounting, cabling for the equipments etc. Also the design have to be optimised to pack all there components and also take the minimum space to maximise the rear storage area.
The parts in the assembly in this design project are:
- Outer Panel upper
- Outer Panel lower
- Inner panel
- Hinge reinforcements
- Gas stay reinforcements
- Wiper reinforcements
- Latch and stricker reinforcements
The input class A surface is extracted.
Tooling Axis
The sheet metal components of the backdoor are manufactured by the process of Deep Drawing. So a tooling axis is created. And all the parts are designed in such a way that it satisfies a minimum draft angle of 7deg with the tooling axis. This is necessary for the life of tools and to decrease the number damaged parts.
Inner Panel Design.:
The outer panel surface is offsetted to a distance of 1.7mm to create the inner panel.
It is again offsetedand trimmed with edge offseted curve to create the sealing surface of the inner panel.
Law extension is created to join it with the main inner panel surface.
Mastic surface in the lower ceter area is created for suppport and reduce vibrations
The cutting also helps in weight reduction and maintaing balance.
Embosses are created to stregthen the inner panel. Sketch and the emboss tool are used to create this.
Emboss are created for the hinge fixing.
Similiarly emboss is also created for gas stay.
Emboss for Wiper motor mounting.
Emboss for latch and stricker.
The surface is mirrored and sewed. Then the sewed surface is thickened to create the body.
Draft Analysis on the body is done.
All the surface is clearing the draft analysis of 7 deg.
Outer Panel
For Both the Outer panels it has to be connected with the inner panel by the process of hemming. Hemming is a forming operation in which the edges of the sheet are folded or folded over another part in order to achieve a tight fit. The clearances of 2mm from inner panel to outer panel end. Also extra folded surface is created for the hemming glue oozing out.
For the lower outer panel the outer surface is ofsetted trimmed and a law extension is is created. The 3 face blend operation is done to create the hemming surface .
For the Upper outer panel, the bridge curve is created and swept along the edge to create the surface.
The reliefs are given on bends and corners on the hemming surface.
Reinforcements are created on necessary regions where there are connections with other parts and stress concentration are created.
The surfaces of the thickened inner panel is extracted and trimmed to create the reinforcements.
Gas stay reinforcements
Draft Analysis
Hinge Reinforecements
Draft Analysis
Latch and striker reinforcements
Wiper motor reinforcements
Assembly
The project design is uploaded in the google drive link given here as advised by mentor, the file size is larger. And the step file is not included as export to step command is not available for student version of the software
https://drive.google.com/drive/folders/1PDR0Gxs-XC65-Hw6vgaX0UVQqw6KDqNT