Design of backdoor
OBJECTIVE:-
The main objective of this project is to learn the Basics of the BIW (Body in white) through designing the Back Door "also referred to as the Tail Gate of a car by considering all the Protocols and Standards of BIW Design.
TAILGATE:-
The Tailgate or the Back door of a car is the Door at the rear end of the car, which provides access to the luggage compartment. In most cars, these back doors are operated with the help of gas stay which in turn reduces the effort required to lift open the door. Some luxury cars have a powered backdoor that is driven by an electric motor. This kind of system is also called a powered trunk lid system. The Back door is also responsible for dissipating the force created while rear collisions, away from coming inside the car.
Major Parts and Reinforcements:
The backdoor consists of the following basic components:
- Backdoor Outer Panel (Upper)
- Backdoor Outer Panel (Lower)
- Backdoor Inner Panel
- Hinge Reinforcements (LH & RH)
- Gas-Stay Reinforcements (LH & RH)
- Latch and Striker Reinforcement
- Wiper motor Reinforcement
BACK DOOR OUTER PANEL:-
As we have the styling surface as the reference we need not work more on the outer panel only need to create the hem flanges after the creation of the inner panel. Here the outer panel of the tailgate consists of two parts which are the Outer panel upper and the Outer panel lower. These two components are joined using the Laser Brazing method
OUTER PANEL UPPER:-
OUTER PANEL LOWER:-
Hemming is done on the outer panel by considering all the parameters.
BACK DOOR INNER PANEL:-
The inner panel is the part that gives enough strength to the outer panel as well as is the part where the viper, latch, hinge, and gas stays are mounted along with the Reinforcements. Modeling of the inner panel is a little Riskier while comparing all the other components of the Back door. The first thing that is created is the sealing flange of the Tailgate
- SEALING FLANGE:-
The sealing flange is the part of the tailgate where it touches and presses the rubber gasket on the Body's side outer in order to avoid the entering of water into the luggage area. The sealing flange is created by offsetting the outer panel to the required distance and also by creating some studio surfaces guided by some bridge curves.
- EMBOSSES FOR HINGE, VIPER MOUNT, GAS STAYS, AND STRIKER:-
The embosses for the hinge, gas stay, viper motor, and striker are positioned appropriately. It is mandatory that the embosses have flat surfaces to be mounted on the panel perfectly.
HINGE EMBOSS:-
GAS STAY EMBOSS:-
STRIKER EMBOSS:-
VIPER MOTOR EMBOSS:-
- FLANGES FOR THE MASTIC:-
Apart from the hemming, the outer panel of the tailgate must be supported using some flanges from the inner panel and some mastics on it. So some cutouts and flanges are created, from the edge of the cutouts the mastic points are created. The distance from the mastic point to the outer panel is maintained at 5 mm
- EMBOSSES FOR DISSIPATION OF COLLISION FORCE AND CUTOUTS FOR WEIGHT REDUCTION:-
To dissipate collision force getting inside the car. Some emboss are made and directed towards the sides of the tailgate. From the embossed surfaces, some materials are removed in order to reduce the weight of the part.
INNER PANEL:-
DRAFT ANALYSIS:-
Reinforcements for Hinge, Gas stay, and Viper mount:-
Reinforcements are used in the areas of sheet metal where other components are attached. The reinforcements compensate Reduced strength of the sheet metal while another component is added to it. Reinforcements are the easier part to create among all other parts in the Tailgate. These are made by using the command wave geometry linker. The proper surface from the inner panel is extracted and trimmed to the desired shape and then thicken to get the Reinforcements.
HINGE REINFORCEMENT:-
GAS STAY REINFORCEMENT:-
STRICKER REINFORCEMENT:-
VIPER MOTOR REINFORCEMENT:-
FINAL DESIGN:-
CONCLUSIONS:-
Backdoor has been created successfully by following all the design considerations and engineering considerations.