Design of backdoor

AIM

To use the provided styling surface to design a back door, and provide the necessary reinforcements and embosses.

INTRODUCTION

The Back Door of a car is the rear most part of the vehicle which gives access to the trunk space of the vehicle. It is also responsible for safety purpose during rear head collision. The rear door also supports the reinforcements and added weights of the wiper motor, gas stay, tail lamps and latch and striker. Mostly aluminium and steel will be used whereas low-budget vehicles use Steel which makes the manufacturing process easy and cost-efficient.

DESIGN METHODOLOGY

TOOLING DIRECTION

Before designing the inner panel of the back door the tooling direction for Deep drawing should be created. This tooling direction is used for draft analysis.

BACKDOOR

INNER PANEL

Inner Panel is the inside of the backdoor where all the emboss, reinforcements are created. It is designed in a way that, when collision happens flow of impact are in upward directon.

OUTER PANEL(UPPER & LOWER)

Outer panel has two separate parts as upper and lower panels. These are mainly used to improve aesthetics of car backdoor. Outer panels are joined with inner panel by hemming process. Also mastics are used in certain area to decrease vibration and noise. So we could get better NVH rating.

Reinforcements comes between the outer panels and inner panel.

Hemming:-It is the process in which the outer and inner pannel is joinned together. A roller a made to roll along the circumference to folds outer panel into the inner panel. Hemming relief is always given into the sharp corner to accomodate bending.

LATCH TRAJECTORY

The position of hinge should be perpendicular to the latch and striker meets for that a circle is drawn from the center of the hinge axis.

HINGE REINFORCEMENT

Hinges are responsible for the opening and closing of a door.

In order to provide more strength to the hinge mounting area, hinge reinforcements are added.

LATCH REINFORCEMENT

Latch is used to lock the door from opening when it should be closed. To provide more strength to mounting area, latch reinforcement is used.

GAS STAY REINFORCEMENT

Gas stay is used to keep the door open when is needed. Gas stay reinforcements are used to increase the strength in that area.

WIPER MOTOR REINFORCEMENT

Wiper motor reinforcement is created to support the mounting area of the wiper motor assembly.

BACKDOOR ASSEMBLY

DRAFT ANALYSIS

Draft analysis is the method to check the clearance of the part in single tooling direction.

The minimum draft angle of 7 degrees.

CONCLUSION

Thus, using the provided styling surface, back door assembly with necessary reinforcements and embosses are designed.