Design of backdoor

BACK DOOR DESIGN REPORT

Aim :

To Develop the Car Back Door by using the given Styling Surface Method by Automotive Sheet Metal Design.

Software Used :

Siemens NX 12.0 (Unigraphics).

Back Door Introduction :

The design of the back door is also known as the Tail Gate. The Back Door is the rearmost part of the car. It also gives access to the cargo space of the car. The back door also supports the reinforcements and added weights such as Wiper Motor, Gas Stay, Hinge, Tail Lamp and Latch and Striker.

A backdoor is the one most of the closure commodities in BIW Sheet Metal Design. The car parts are made of steel or aluminium based on the car's budget. The back door has a lot of components inside the panel. It also affects the rear visibility and luggage area. The material used for door manufacturing depends upon the budget and performance of the car.

Nowadays most car manufacturers are trying to use Aluminium instead of steel and they reduce the number of parts and weight of the car drastically.

Major Parts and Reinforcements :

Components of the back door :

1. Back Door Outer Panel (Upper)

2. Back Door Outer Panel (Lower)

3. Back Door Inner Panel

4. Hinge Reinforcements (LH & RH)

5. Gas Stay Reinforcements (LH & RH)

6. Latch and Striker Reinforcement

7. Wiper Motor Reinforcement

TailGate:

TailGate is a door at the back of cargo or car, that is hinged at the bottom so that it opens downwards.

Design of Back Door Inner Panel :

• Inner Panel extracted from a styling surface of a back door.
• The thickness provided for Inner Panel is 0.75 mm.
• The inner panel is designed depending upon the outer panel, primarily the sealing flanges are designed and then the using law extensions are connecting to flanges are designed.
• Then the embosses, cutouts are created and also supports the flanges cutouts.
• Then the connection for the reinforcements are also designed

Tool Direction:

Back Door Outer Panel (Upper):

• The outer upper panel is extracted from a styling surface of a back door.
• The hemming is provided for the upper panel and the hemming surface provide corner relief.
• The thickness provided for the upper panel is 0.75 mm.

Back Door Outer Panel (Lower):

• The outer lower panel is extracted from a styling surface of a back door.
• The hemming is provided for the upper panel and the hemming surface provide corner relief.
• The thickness provided for the lower panel is 0.75 mm.

Back Door Outer Panel (Upper & Lower) :

Design Intent :

The project intends to design a Body In the White Back Door of the car considering the engineering standards and manufacturing requirements. It also satisfies the Deep Drawing Process.

Hemming :

• Hemming is a forming operation in which the sheet is folded.
• Hemming is the assembly as a secondary operation after deep drawing and using the trim operation is separate to inner panel small portion cuts the hemming.
• Hemming thickness is 0.75 mm.
• Hemming and seaming are two similar sheet metal processes.

Corner Relief:

Relief helps to control the sheet metal material behaviour and prevent the unwanted portion remove using the trim So I gave two corner reliefs for the back door.

Back Door Outer Panel (Upper) :

Back Door Outer Panel (Lower) :

Back Door Assembly:

Mastic Sealants:

The mastic sealant is used to fix the inner panel with the outer panel. It also increases the NVH factor and improves the strength of the back door.

Hinge Reinforcement(LH & RH) :

• Reinforcement is created by using the wave Geometry Linker option.
• Prevent the unwanted portion removed by using the trim option.
• Hinge Reinforcement Thickness is 1.5 mm.

Gas Stay Reinforcement (LH & RH) :

• Reinforcement is created by using the wave Geometry Linker option.
• Prevent the unwanted portion removed by using the trim option
• Gas Stay Reinforcement thickness is 1.5 mm.

Wiper Motor Reinforcement :

• Reinforcement is created by using the wave Geometry Linker option.
• Prevent the unwanted portion removed by using the trim option.
• Wiper Motor Reinforcement thickness is 1.5 mm.

Latch and Striker Reinforcement :

• Reinforcement is created by using the wave Geometry Linker option.
• Prevent the unwanted portion removed by using the trim option.
• Striker Reinforcement thickness is 1.5 mm.

Reinforcements for Mounts space:

Striker Placement:

The hinge should be perpendicular to the latch when the latch and striker are met. the circle is drawn from the centre of the hinge axis to find the path of the striker and positioned is perpendicular to the path.

Various Views of the Back Door:

Front View:

Back View:

Side View:

Isometric View:

Draft Analysis :

• Draft Analysis shows that ready to manufacturing the part of back door inner panel.
• Draft Analysis is clearance with the tool direction and also easily the mould.

Final Conclusion :

• Thus the back door has been designed from the given BIW Surface.
• Draft Analysis is completed on the inner panel to check the manufacturing conditions.
• In this challenge, I prepared my way to design the Inner Panel, the Outer Panel, Wiper Motor Reinforcement, Hinge Reinforcements, Gas Stay Reinforcements and striker reinforcement and its position