Design of backdoor
OBJECTIVE:
To Develop the Car Back Door by Using given Styling Surface Method by Automotive sheet metal design.
TOOL USED: NX CAD
Introduction:
Design of back door is also called as the Tail gate. A car back door which is consists 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 with which they can reduce the number of parts and weight of the car drastically.
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 PANNEL:
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.
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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 Gas Stay System: This mechanism is most used in India cars. It is operated man on his own.
- Power lift Gas Stay system: It works on the basics of Sensor.
Latch and striker Reinforcement:
Latch placement is done by determining the axis of the hinge and a circle is drawn through the middle of the lower end of the back door and the latch is placed perpendicular to it. It is better viewed in the diagram below:
Wiper Motor Reinforcement:
Wiper Motor is a small electric motor used to move the wiper through and fro for better visibility through the glass of the back door.
All Mountings Together:
HEMMING OF THE OUUTER PANNEL AND RELIEF:
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.
Entire Tail Gate Assembly: