Challenge

Design of backdoor

AIM : To develop back door or tail gate from given outer panel under design guideline and regulation.

OBJECTIVE :

INTRODUCTION :

TAIL GATE :

The tail gate or back door iof a car is the door at the rear or back end of the car.
It is access to the lugguage compartment.
Some luxury car have powerback doorswhich is driven by electric motor.
In most of the car's, these this tail gate are operated with the help of gas stay which is trn into reduce the effort required to to lift open the door.

The main parst's of the back door

Class-A

In automotive industry every product is goes through a Product Life Cycle, where at initial stage concept validation is done.
After that there is a dedicated team who develop ordesign Aesthetic surface of a complete product which is called as a Class-A surface.

Design Methodology :

In this Perticular product we took Top down approach, where we create parts in assembly.

Tooling Direction :

While designing any product or part it is very important to give tooling direction .
Which is help to manufacture the product by deep drawing process.
In deep drawing process have atool which hava a core and die. The core part follows the tooling direction.

Outer Panel :

Tail gate outer panel is a another BIW component of vehicle. Like other BIW part here also we provides coating of multi stage which has property of scratch resistance, rust prevention and smoot finish and attractive surfaces.
In outer panel there is provision for a tail lamp, rear fog lamp and also has a provision for licence plate mounting.
Most of the hatch back car have the provision for wiper motor.

Inner panel :

Innner panel is created for provide srength to the outer panel or door assembly. Also in inner panel panel all accessories like gas stay, hinge, wiper motor, and striker are mounted.
It is mounted with the roof. The weight of the inner panel is about 7 to 8 kg depends upon the material and thickness.

Embosses :

To provide strength to back door or tail gate when collision is happens, we have to create emboss on inner panel in such way that the force get distributed over inner panel and cause minimum damage.
The draft angle is provided too the embosses should be 7 to 25 degree.

Hinge :

Hinge is used to connect the tail gate to the BIW also enable to opening and closing of the hood.
So emboses are created of the hinge along with reinforcement to provide additional support to the inner panel.
The hinge are created at the top of the inner panel, it is give access to attach or join tail gate to the car BIW.

Gas Stay :

Gas stay is a device used for supporting the back door in its opning position. Gas stay requires no human power and its engaged into support position automatically as the back door opens.
One end of the gas stay is fixed on the back door and other end on the body side or on the backdoor stationary area.
Embosses is provided at the gas stay mounting area to compensate for the functional holes punches.

Latch and Striker Reinforcement :

The latch and striker form the locking mechanism of the backdoor with the car. Due to regular opning and closing, and over slamming of the back door, there is stress developed in the latch and strker area.

Reinforcement :

Reinforcement and embosses are added or designed to compensate the loss of strength in a region or area due to load acting there. In the back door case load act in the form of hinge, gas stay, and Latch and striker.

Draft Aanlysis :

As we know, we provide draft angle to every component fro dep drawing procees. Draft Analysis we can check the draft angle is correct or not.

Ship work like this
in your own course.