Design of backdoor

AIM:

To design and develop the Inner Panel and reinforcements for the Backdoor from the given class-A surface recieved from the styling department, ready for production.

AGENDA:

• To design the inner panel and Flanges for the given tailgate design.
• To perform Draft Analysis on the the components developed.
• To create the reinforcements for the Hinge,Gas stays and Latch.
• To create striker according to the Trajectory.

THESIS:

The backdoor is a Door which is used to access the Boot/Luggage compartment. The backdoor houses various components like the Rear windsheild, hinge,striker,Reinforcements and wiper Motor.

PROCEDURE:

The Outer panel Class-A is received from the Styling Team. we have to seperated the outerpanel into 2, 1 as the "Upper Outer Panel" , and 2 as the "Lower Outer Panel".

Given Class-A surface:

Upper Outer Panel:

Lower Outer Panel:

Inner Panel creation:

The Inner panel is a single panel which is accomodates the both the Outer panels and the attachements are done by Mastics, Spot Welding and Hemming.The inner panel should be having openings to access the Wiper motor for servicability. it should having Embosses for structural rigidity and flanges for mating.

Creating the Emobosses and cutouts for Structural rigidity:

Creation of Wiper Flange and Mastic Flange:

Creation of Hinge Deboss.

Tracjectory for Striker location:

The Trajectory for the striker is created by drawing a circle around the Hinge Axis and locating the intersection of the Trajectory (circle) at where it intersects the Inner panel. The striker is created at this point to ensure proper latching of the Backdoor when closed. this is very essential since it ensures proper sealing of the door panel with the rubber flange. Improper sealing may lead to leakage of water during wet conditions and road noise being heard inside the cabin due to air leak.

Creation of Striker Emboss:

Creation of Reinforcements:

Gas-Stay reinforcement:

Hinge Reinforcement:

Striker Reinforcement:

Wiper Motor Reinforcement:

Draft Analysis:

Inner Panel Draft analysis:

Hinge reinforcement:

Gas stay Reinforcement:

Striker Reinforcement:

Wiper motor reinforcement:

Final Images of the completed component.

Inner panel:

Inner panel Finished in Antracite Black.

Outer Panel :

Outer panel Finished Rosso Scuderia:

CONCLUSION:

The given Class-A from the styling team was developed into a fully functional component and is ready for Testing and Production.