Design of backdoor

CAR BACK DOOR
DESIGN
Aim:
To design back door of car using given outer class 'A' surface.
What is back door of a car?
A door which is located at the rear side of a car which gives access for the boot space to store luggage, spare wheel etc.
These doors can be operated manually or electric powered. In most of the luxury cars door is electrically operated.

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Types of doors based on working position,
1.Top Mounted Door
2.Side mounted Door
3.Bottom Door

Gas Stay Powered:

Electric Operated:
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Back Door Assembly:
Inner panel
outer panel
hinge and its reinforcement
wiper motor reinforcement
latch & stricker and its reinforcement

Different Sheetmetal processes used for manufacturing the Back Door
Deep Drawing:
The metal deep drawing process is an effective method of manufacturing of cups, cans and other similar deep drawing products.The deep drawings having two main categories.
1.First- stage drawing:
The blank shape of metal is placed on the die and contact with the punch. When the metal specimen isflat piece of sheet metal used in forming and finish the product. Initially the punch moves in downward direction. The outerrim of blank is subjected to pure radial drawing (drawing toward in vertical axes) between die and blank metal. The metalbecome a bend and sliding over die and also stretched between die and punch. The metal in vicinity of punch head andcontact with it bend and slide over radii and stretch over punch head.
2.Redrawing:
The components drawn from first stage again it is redrawn convert into more depth to form a cup shape in thedie and punch. The second stage of drawing is called as redrawing.

Embossing:
Embossing is a metal forming process for producing raised or sunken designs or relief in sheet materials by means of matchedmale and female roller dies, theoretically with no change in metal thickness or by-passing sheet or a strip of metal between rollsof the desired pattern.
Metal sheet is drawn through the male and female roller dies producing a pattern or design on the metalsheet. Depending on the roller dies used, different patterns can be produced on the metal sheet.
Materials commonly used in the metal embossing process include:
Aluminum alloys
Steel alloys
Zinc
Copper
Galvanized steel
Brass
Cold rolled steel

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 tightfit. Normally hemming operations are used to connect parts together, to improve the appearance of a part and to reinforce partedges.
In car part production, hemming is used in assembly as a secondary operation after deep drawing, trimming and flangingoperations to join two sheet metal parts (outer and inner) together. Typical parts for this type of assembly are hoods, doors, trunklids and fenders.
There are various types of hemming operations:
1.Conventional die hemming:
In conventional die hemming, the flange is folded over the entire length with a hemming tool.
2.Roll hemming:
In roll hemming, the hemming roller is guided by an industrial robot to form the flange.

Open Hem:
A Hem has a full round feature and a return flange. In open hem bend angle is equal to 180 degrees.
Tear drop Hem:In tear drop hem the bend angle is greater than 180 degrees.
Closed Hem:Hems without any inside radius are called as closed hem. Closed hems are not recommended if the hem geometryis to be painted or if the material used is SST or Aluminium.

Blanking:
Blanking is a cutting operation of a flat metal sheet and the article punched out is known as blank.
Blank is the required product ofthe operation and the metal left behind is considered as a waste.
Punching:It is similar to blanking only the main difference is that, the hole is the required product and the material punched out from thehole is considered as a waste.

Design of Back door in NX CAD:
Door parts thickness is given below,
1.Outer Panel - 0.75 mm
2.Inner Panel - 0.75 mm
3.Reinforcements - 1.5 mm

Given Data,

Given surfaces has to be repaired according to the smoothness. After repairing the surfaces, the door is divided into two parts asDoor Outer Upper and Doo Lower Panel.

First, we need to create the Tooling direction for the Deep drawing operation. It shows that all the operations like embossing isdone by considering this vector direction and it will help in manufacturing the part,First, we need to create the Tooling direction for the Deep drawing operation. It shows that all the operations like embossing isdone by considering this vector direction and it will help in manufacturing the part,

Then we will be creating the Back door inner panel flange by offsetting the outer surface at a distance considering the sheetthickness and thickening direction.
Then created the connecting flange to join the inner panel and sealing flange.
Then for the windshield panel mounting, windshield panel is created and joined with sealing flange.Then to improve the strength of the inner panel and to reduce the weight 'Y' type emboss and other cut-outs are created. Also,for Latch and Stricker mounting cut-out is created. This cut-out is also done on other side of the inner panel to maintain thecentre of gravity of the Back door.
Another Emboss is created for Wiper motor mounting.

Now to assemble the back door with the vehicle Hinges are used to open and close the door. For that to increase the local areastrength we have to design the emboss and provide the appropriate reinforcements to withstand the load acting upon it.