Design of backdoor

                                             DESIGN OF BACKDOOR

AIM:

          To Design a Backdoor of the car on Sheet metal using the appropriate design and provided skin data by considering design parameters.

Objective:

·    To design a Backdoor of a car with an Inner Panel, Outer Panel and Reinforcements for Hinges, Gas Stay, Wiper Motor and Latch.

·    In Inner Panel which is subjected to Draft Analysis, so I had to ensure whether it is satisfying the deep drawing requirements for the Tooling direction that is created in this design.

INTRODUCTION:

The Backdoor of a car, also known as the Rear door or Tailgate, is a movable panel typically located at the rear of the Vehicles. It provides access to the cargo area or rear seats of the car. The design and construction of the backdoor vary depending on the type of vehicle (e.g. Sedan, SUV, Hatchback) and its intended use.

The Backdoor of a car is a Component which hinges at the back of the car to cover the boot space or luggage area, but there are more functions that come with it which must be considered while making a design of the same like rear visibility criteria and boot space.

It has Backlights/Tail Lamps and Braking lights which termed as ‘Third Brake light’ mounts on it, rear wind shield fixes between Inner and Outer panel, in some Backdoor spare wheel can be mounted on it, sometimes car registration number plate mounts on it and it gives a complete closed design to the car.

Types of Backdoor in a Car:

·      Top Mounted Door

·      Side Mounted Door

·      Bottom Mounted Door

Some Components of Backdoor:

·        Inner Panel

·        Outer Panel (Upper/ Lower)

·        Hinge Reinforcements (LH/ RH)

·        Gas Stay (LH/ RH)

·        Wiper Motor Reinforcements

·        Latch Reinforcements

Design Intent:

The intent of this project is to design the BIW Backdoor of the Vehicle by following the Engineering standards and manufacturing requirements which satisfies the deep drawing process.

Methodology of Backdoor Design:

For designing the Backdoor firstly, I must check if there are any surface irregularities in the given Skin data, if there are any irregularities then I must repair it by using appropriate commands.

After Improving Given Skin Data then I create Sealing Flange, generally we design the panel with appropriate dimensions with the help of Master section. But in this Design, there is no Master Section given, so I designed by assumption.

(Here is Improved Class A pic).

 Tooling Axis:

The Tooling Direction/Axis is created so that the manufacturing team take the reference of this tooling axis and manufacture the part accordingly. It is designed by using Top-down approach.

Outer Panel:

The Outer panel of the Backdoor is like the other BIW components where it is the aesthetic part of the vehicle. The coating provided is of full multi stage which has the property of scratch resistance, rust prevention, and smooth and attractive finishes. The Outer panel also has the provisions for the Tail Lamp, Rear Fog Lamp and has the provision for License plate mountings. Most of the Hatchback cars have the provision for Wiper Motor.

Inner Panel:

The Inner panel is a component which is sed for strengthen the door assembly and it is one of the most important components on which all accessories are mounted like Hinges, Gas Stay, Glass Guide Channel, Molded Trim, Latch, etc. The possible method is the integration method. In Integration method the part is stamped out of a single blank. This reduces the number of tools needed, the assembly cost and eliminates any fit ability problem.

Sealing Flange:

 It is that section of the inner panel which enables the backdoor to sit over the rear body side of the car. Its design is important as it decides how a backdoor is mounted on the rear body side of the car and restricts any external matter to enter inside the vehicle.

Mastic Region:

The "mastic region" in the context of a car's backdoor inner panel likely refers to a section where mastic or sealant is applied. Mastic is a type of flexible adhesive commonly used in automotive manufacturing to seal gaps, joints, and seams.

In the context of a backdoor inner panel, mastic may be applied along the edges or seams of the panel where it meets other components, such as the outer panel, to create a watertight and airtight seal. This helps prevent water, dust, and noise from entering the vehicle's interior and helps improve the overall structural integrity of the backdoor.

Emboss and Reinforcements:

With the distinctive cross section, embosses are created. These embosses are used to increase the strength of the backdoor. While designing we should keep in mind that it should not be over strength. So, we prefer to design big embosses rather than small embosses. These embosses are used to despite the forces sideways.

Hinge:

Gas Stay:

Wiper Motor:

Latch Striker:

Hemming:

In this Backdoor design I need to provide Hem relief in each corner of outer panel.

Provided clearence for hem glue is taking reference of Hood Design Master section 0.2mm gap both sides

Thickness:

Thickness of the backdoor Inner and Outer Panel is 0.75 each, the Clearence between them is 0.2mm.

Draft Analysis:

After Completing Backdoor Inner Panel I to perform Draft Analysis on it, draft direction is tooling axis with a minimum draft angle of 7degree (6.95).

Conclusion:

  In this design I learned about backdoor design consideration and its reinforcement features.

NOTE: Backdoor design folder is more than 20mb. after compressing to zip file and winrar file, So I uploaded without stp. file and here in answer box I attached a google drive link with part file and product file as well as stp. file is uploaded in google drive link please have a look.

      https://drive.google.com/drive/folders/1b9NghFLeR6OslDXQ8yzs4xDe-bcjI6Gw?usp=sharing

                                     Thankyou