Design of backdoor
Aim: To design a Back Door by using given styling surface by providing all the necessary rienforcement and embosses and by considering the appropriate design parameters.
INTROUCTION :
A door is a hinged part which is used for the entry and exit of the vehicles . Back door are the one of the type doors of the vehicle which is locate located next to the passenger seat which provides acces to the luggage compartment.
Types of Back Door :
Top- Mounted:
This type of back door is used in a station wagon, Pickup truck and some of the sport utility vehicles. Todays modern cars use top-mounted tailgate system which are both powered and also gas stay supporte. These Top mounted tailgates provide greater rear visibility compared to side mounted or bar doors which have canter pillars in it.
Side Mounted Doors:
As the name signifies side mounted doors are one which is used in the van type MPVs, SUVs, pickup truck vehickes. These side mounted doors or bam doors are a lot easie compared to top mounted doors. These doors are more convinientfo the good handlers for long pipe and lenghty components where one door is kept open.These doors also save accidental head impacts it is easier to load and unload items in the side mounted doors.
Bottom or Split Type:
This bottom type or split type backoor system are used in the car type such as estate type car, pickup trucks and some luxury SUVs. These are the most convininent type of back door in which the bottom split is used as support or even as a table for the tour going people.
Types of Mechanism of Back Door:
Gas stays type:
Gas stay types back door is an ideal and most commonly used tailgate mechanism from lower segment car to luxury car segment. The ideal components of tailgate consists of a hinge, door, gas, an some rubber beadings for sealing of door.
Powered Lift System:
Power trunk lid system is another sophisticated way of tailgate opening mechanism which is to automatically open and close of the tailgate and release of the latch by the touch of a bottom.
DIFFERENTS METHODS OF MANUFACTURING OF BACK CAR DOOR :
Blanking:
Blanking is a metal fabricating process, during which a metal workpiece is removed from the primary metal strip or sheet when it is punched. The material that is removed is the new metal workpiece or blank. The ability to produce holes of varying shapes – quickly.
Deep Drawing:
Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter.
Trimming:
Trimming is a manufacturing process that is used as a finishing operation for forged parts, in order to remove flash.Trimming basically presses a part through a cutting die that runs the periphery of the work.
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.In car part production, hemming is used in assembly as a secondary operation after deep drawing, trimming and flanging operations to join two sheet metal parts (outer and inner) together. Typical parts for this type of assembly are hoods, doors, trunk lids and fenders.
Design Consideration:
- Rear visibility
- Hinges and Gas stays
- Fit and Clearance
- Boot spaces and accessibility
PROCEDURE:
BACK DOOR ASSEMBLY:
The Back door assembly of the car has the following components:
- Inner panel
- Outer panel
- Hinge rienforcement
- Gas stay rienforcement
- Wiper motor rienforcement
- Latch/Striker rienforcement
DESIGN OF INNER PANEL:
The inner panel is a component which is used for strengthening the door assembly and it is one of the most important components on which all acccessories are mounted like hinges, Glass guide channel, moulded trim, latch etc. The possible method is the integration method, In the integration method, The part is samped out of a single blank. This reduces the number of tools neededfor the assembly cost and eliminates any fit ability problem. The inner panel is designed by the given Class A surfece as per the given mastersection. The inner panel consist of Embosses and Mastics.
DESIGN OF OUTER PANEL:
The outer panel of the back door is similar to the other BIW components where it is the asthetic part of the vehicle. The coating provided is of multi stage which has a property of scratch resistance, rust prevention and smooth and attractive finishes. The outer panel has provision for the tail lamp, rear fog lamp, and also has the provision for the license plate mountings. Most of the hatchback cars have provision for wiper motor.
Upper Panel:
Lower Panel:
DESIGN OF REINFORCEMENT
Reinforcement basically strenghts or increases the mechanical properties of the materia, The hinge reinforcement are provided as to increase the strength during bolting.
The different types of reinforcement:
- Hinge reinforcement
- Gas stay reinforcement
- wiper motor reinforcement
- Latch/striker reinforcement
Design of 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.
DRAFT ANALYSIS:
Parts cannot be ejected from the tool if it is at 90- degree for this reason, a small draft is to be provided for each surface for the components in order to easily remove the components from the mould without any defects. Draft is the angle in which the part is tapered to allow it to release. Most of the sheet metal part require minimum 7 degree to 10 degree however 7 degree is widely accepted in sheet metal components design.
FINAL MODEL IMAGE:
CONCLUSION:
Thus, The car back door was designed by considering all the design parameters in to account.