Design of backdoor

AIM

To design the inner panel of the backdoor/tailgate for the given skin data along with the required reinforcements such as gas stay reinforcement, latch and striker reinforcement, wiper motor reinforcement and hinge reinforcement.

INTRODUCTION

Backdoor/ tailgate at the back of a wagon, truck, station wagon, etc. which is located at the backside of the vehicle to access the luggage compartment.

MATERIAL COMPARISON

The two important materials are used for BIW components such as aluminium and steel.

ALUMINIUM -Parts are casted and thickness can be varied throughout the panel. Reinforcements is not needed hence lighter in weight. Using aluminium ultimately reduces the final mass of part produced compared to steel, but the price and the manufacturing cost is higher.

Aluminium is a better metal to use for outdoor signs because it has better weather resistance than steel.

Density (AL) = 2.7g / cubic meter

STEEL - Parts are stamped and have uniform thickness. Reinforcements must be given to increase strength locally. . compared to the aluminium the weight of steel is higher. Steel, however, has superior in strength.

Density (steel) = 8.05g / cubic meter

PROCEDURE

• Inner panel

The inner panel is designed to give strength to the outer panel. The embosses are provided to give strength and it can be of V or Y shaped since these shapes helps in dissipating the energy away from the passenger compartment during a collision.

The circle has to created such that the striker’s tip is positioned in such a way that it perfectly follows the trajectory with hinge axis as centre to achieve proper opening and closing of the tailgate.

• Hinge reinforcement

To increase the strength of the region, hinge reinforcement has been provided.

Momentum of inertia

• Gas Stay reinforcement

To increase the strength of the region, gas stay reinforcement has been provided.

Momentum of inertia

• Latch and striker reinforcement

To increase the strength of the region, latch and striker reinforcement has been provided.

Momentum of inertia

• Wiper motor reinforcement

To increase the strength of the region, wiper mounting reinforcement has been provided.

Momentum of inertia

• Mastic mounting region

This region is provided to place the mastic sealant to join the outer and inner

• Back door outer panel

It consists of lower and upper outer panel as shown in the image for the outer panels we provided the hem to join the inner and the outer panel

• Sealing flange

A weather strip is placed between the inner panel and the sealing flange in body. This rubber is deformed when backdoor is closed and gets rebuild when opened. While designing the sealing flange we need to remember of the boot space.

• Hem and relief

Hem is provided to join the inner and the outer panel and Reliefs are provided at the corners in order prevent the overlapping surfaces.

DRAFT ANALYSIS

It is carried out to check if there is any negative draft in the designed model and if the negative draft exists then it indicates that it cannot be manufactured.

CONCLUSION

The inner panel and the required reinforcements were successfully designed using the Siemens NX software