Design of backdoor

                                                               Design of Backdoor using NX 12

Aim :

The motive of this project is to design the backdoor inner panel, hinge, gas stay, wiper motor, and striker reinforcements from the styling surface received.

And to check the manufacturing feasibility by doing a draft analysis.

BackDoor / Tailgate:

The backdoor/Tailgate is the hinged assembly in the rear part of the vehicle which gives access to the boot space. This tailgate design changes with vehicle types like sedan cars will not have a glass panel in the back door assembly while SUVs and hatchbacks will have a glass panel with the assembly.

Back door assembly consists of :

• Outer Panel upper and Lower
• Inner panel
• Hinge Reinforcements
• Latch Reinforcement
• Gas stays Mounting Reinforcements
• Wiper Motor Reinforcements

Design of Inner Panel:

The first thing is to determine the tooling axis for the inner panel.

The inner panel flange comes in contact with the sealing flange in a closed condition. So the flange emboss is created with the required dimension considering closing and boot space.

Next is to create v emboss and other emboss in the backdoor inner panel to increase its strength, maintain the center of gravity, and have a proper flow of forces.

It also helps to pass the various load cases through the back door.

Design of Hinge embosses:

Design of Gas stay mounting:

Design of Wiper Motor Mounting:

Design of Striker Mounting:

For striker Mounting, it is very important to determine the hinge axis and from the hinge axis, a circle is created according to the striker's location and a tangent line is created where the tangent line coincides with the striker's pin's axis. From this, we can determine the location of the striker.

Reinforcements:

Reinforcements are generally used locally to improve the strength of the region. They are usually thicker than the outer and inner panels which are 1.5mm.

Hinge Reinforcement:

Gas Stay reinforcement:

Wiper Motor Reinforcement:

Striker Reinforcement:

Draft analysis:

Manufacturing:

The sheet metal parts are manufactured mostly by stamping and another process like casting can be done with material like aluminum.

For stamping, the draft clearance is very important, and a draft of 7 deg is used and verified using draft analysis along the tooling direction.

Like the hood, the outer panels and inner panels are hemmed. 

Hemming and Corner Relief:

Conclusion:

From the given styling surface of the back door, the inner panel and all reinforcements were created and assembled. Draft analysis on the inner panel and reinforcements are done. Finally, the outer panels and inner panels are hemmed together with necessary reliefs at the corner.