Design of backdoor

Car Back Door Design:

Objective: Design back door of the car help of given surface from styling team.

Back Door: The back door or boot of a car is the vehicle main storage or Cargo compartment, often a hatch at the rear of the vehicle. a backdoor is located at the rear end of the car. Backdoor can be open manually and electrical some of the expensive car using remote control opening system. Backdoor holding taillamp, wiper motor and hinges.

Main Component of the Back door Design:

• Inner Panel
• Outer Panel
• Hinge Reinforcement
• Gas stay Reinforcement
• Wiper Motor Reinforcement
• Latch and Striker Reinforcement

Details of the Component:

Inner Panel: As per the Class A reference surface we have to create the inner panel of the backdoor . Now a days making of car back door steel and aluminums material using but for the premier’s level of car OEM’s using Aluminum material. we will see step step design of inner panel.

• We have taken reference of the styling surface of the upper and lower and we have make tooling direction for our help to manufactured easily.
• We have used offset Face comment and make line as per our requirement and used trim sheet comment and remove unwanted sheet. As per the requirement sealing flange should be more than 25mm. we have kept 30mm.

• We have connected body used of Law extension comment & angle kept 30 degree and used trim and extended comment and we have made outer flange and aging we taken offset surface comment and made inside Flange.
• Inner panel surface ready we have given emboss on the surface to increase body strength and one cutout also done for easier assembly process. Emboss given as per Tooling direction for easier manufacturing process.
• In the inner panel we have created mounted Gas stay hole and wiper motor hole, Latch and Stricker hole and Hinge Hole also.
• Positioning the Latch & striker, we have sketch trajectory line and based on line we have drawn one circle, that circle should passthrough midpoint of two mounting hole.
  
• After completing all the emboss process we have used mirror Geometry comment and thicken inner pane 0.75mm Upward direction.

Outer Panel: In this Design we have two outer panel, one lower outer panel another one upper outer panel. Car back door aesthetics look depend on outer panel only. Outer panel and inner panel connecting by hemming process and make more strength we have given mastic sealant also. for mastic sealant we have maintain 5mm Gap. Outer panel manufacture through metal stamping process.

Metal stamping: Stamping (also known as pressing) is the process of placing flat sheet metal in either back or coil from into stamping press where a tool and die surface forms the metal into a net shape. Metal stamping is a manufacturing process used to convert flat metal sheet into specific shape. It’s a complex process that can include a number of metals forming techniques -blanking, Punching, Bending and piercing etc.

Hemming: Hemming is a forming operation in which the edge of the sheet are folded over another part in order to achieve a tight fit. Normally hemming operation are used to connect parts together to improve the appearance of a part and to reinforce part edge.

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.

There are various types of hemming operation -1) Conventional Die hemming

2) Roll Hemming

NX outer Panel Design Step:

• With the help of Wave Geometry linker, he has created same outer panel than extracted the same body.
• Used offset surface comment and created one more surface at the below distance of 2.65mm.
• Used offset Face comment and make one-line entire sheet metal 10mm and used trim sheet comment, cut unwanted sheet.
• Used bridge curve and swept for make hemming for outer panel and inner panel connection.
• We have done Sew and mirror geometry and given thickness 0.75mm.
• Outer lower panel also used same comment.
• 
• 
• 

Reinforcement: We are giving Reinforcement because we have to make those portion more strength. We can’t do this operation one short with our inner panel if we are not using some development material like aluminums. We are manufacturing those part with casting operation. Here we have design separate Reinforcement for all. We have given thickness 1mm for the reinforcement toward upward direction.

• Help of Wave geometry linker we have taken those shape
• We have cut unwanted portion with the help of trim sheet metal
• Given thickness 1mm toward upward direction.

Draft Analysis:

Inner Panel:

Outer Panel Upper:

Outer Panel lower:

Wiper Motor Reinforcement:

Latch and striker Reinforcement:

Relief: Corner area we have to use relief as per requirement or standard if we keep as it is then at corner area it will create more stress than other area.

Final assembly sketch:

Assembly Navigator:

Conclusion: Car back door design was completed as per given requirement in the NX software.