Design of backdoor

DESIGN OF BACK DOOR OF THE CAR BY USING NX CAD

Objective :

To Develop the Car Back Door by Using given Styling Surface Method by Automotive sheet metal design. Tool Used :- Nx12

Introduction :

Design of back door is also called as the Tail gate. A car back door which is consist of Inner panel, Outer panel. Basically the car parts are made of Steel or Aluminium based on the budget of the car.

Using Aluminium improve the Strength where we can avoid the reinforcements. Aluminium parts are casted and we can vary the thickness of the part, because of this avoid or reduce the number of parts as compared to Steel. Only drawback is the cost of aluminium, which is high cast As compared to steel.

Steel Parts are stamped, we cannot vary the thickness of the part because of more number of parts are added. Which could increase the weight of the part?

So now a day’s most of the car manufacturers are trying to use Aluminium instead of Steel and they reduce the number of parts and weight of the car drastically.

	Steel	Aluminium
Parts	parts are stamped	parts are casted
Reinforcement	Necessary	Can be neglected
Thickness	Constant	Can be varied
Components	More	Less in number
Weight	More	Lighter
Cost	Less in Cost As compared to Al More	As compared to Steel

Components of the Back Door:

• Outer panel upper
• Outer panel Lower
• Inner panel
• Latch and Striker Reinforcement
• Hinge Reinforcement
• Gas stay Reinforcement
• Wiper motor reinforcement

Design consideration for a back door:

• Rear Visibility
• Boot Space and accessibility
• Fit and Clearance
• Support Structures like hinge and gas stays
• Mounts for wiper motor, tail lamps, and other wiring loops.

Inner panel:

Emboss:

Sheet metal embossing is a stamping process for producing raised or sunken design or relief in sheet metal. This process can be made by means of matched male and female roller dies or by passing sheet or a strip of metal between rolls of the desired pattern.

Embossing is done by pressing a sheet of par=per in to female die, That has a design etched into it. This is usually done with a male counterpart underneath the paper so that the two and the design is transferred to the paper.

Force Distribution:

When the car hit at rear end, the force which acted should be react outside. The Y/V emboss which is helps to move the force to the outer end.

Hinge Reinforcement:

Hinges are the essential that allows doors to pivot on one edged as open as they open and close. They are found on virtually all doors. It is a mechanical bearing that connects two solid objects, typically allowing only a limited angle of rotation between them.

Gas stay reinforcement:

It is used to lift up the Tail gate.

They are two types of Gas stay reinforcement is there. That they are

• Manual System
• Power lift system
• Manual system

This mechanism is most used in India cars. It is operated man by his own.

• Power Lift System :

It works on the basics of Sensor.

Latch and striker Reinforcement:

Wiper motor reinforcement:

It is small electric motor which is mounted in the rear tail gate. It used to clean the rear wind shied for clear visibility.

Outer panel:

Outer Upper Panel:

Outer inner panel:

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. Normally hemming operations are used to connect parts together, to improve the appearance of a part and to reinforce part edges.

Hemming is used in assembly as a secondary operation after deep drawing, trimming and flanging operation to join two sheet metal parts(outer and inner ) together.

The accuracy of the hemming operation is very important since it affects the appearance of the surface and surface quality.

Back Door Assembly:

Conclusion:

The design of the Back door BIW was completed with the engineering standard and all the reinforcements