Design of backdoor

*Developing Car Back Door by Using given Styling Surface Method by Automotive sheet metal design.

Tool Used :- CATIA V5.

Introduction :

Design of back door is also called as the Tail gate. A car back door which is consist of Inner panel, Outer panel. Basically the car parts are made of Steel or Aluminium based on the budget of the car.

Using Aluminium improve the Strength where we can avoid the reinforcements. Aluminium parts are casted and we can very the thickness of the part, because of this avoid or reduce the number of parts as compared to Steel. Only drawback is the cost of aluminium, which is high cast As compared to steel.

Steel Parts are stamped, we cannot vary the thickness of the part because of more number of parts are added. which could increase the weight of the part.

So now a days most of the car manufacturers are trying to use Aluminium instead of Steel and they reduce the number of parts and weight of the car drastically.

Steel Aluminium

Parts parts are stamped parts are casted

Reinforcement Necessary Can be neglected

Thickness Constant Can be varied

Components More Less in number

Weight More Lighter

Cost Less in Cost As compared to Al More As compared to Steel

Components of the Back Door :

Outer panel upper

Outer panel Lower

Inner panel

Latch and Striker Reinforcement

Hinge Reinforcement

Gas stay Reinforcement

Wiper motor reinforcement

Design consideration for a back door :

Rear Visibility

Boot Space and accessibility

Fit and Clearance

Support Structures like hinge and gas stays

Mounts for wiper motor, tail lamps, and other wiring loops.

Inner panel :

Emboss:

Sheet metal embossing is a stamping process for producing raised or sunken design or relief in sheet metal. This process can be made by means of matched male and female roller dies or by passing sheet or a strip of metal between rolls of the desired pattern.

Embossing is done by pressing a sheet of par=per in to female die, That has a design etched into it. This is usually done with a male counter part underneath the paper so that the two and the design is transferred to the paper.

Force Distribution:

When the car hit at rear end, the force which acted should be react outside. The Y/V emboss which is helps to move the force to the outer end.

Hinge Reinforcement:

Hinges are the essential, that allows doors to pivot on one edged as open as they open and close. They are found on virtually all doors. It is a mechanical bearing that connects two solid objects, typically allowing only a limited angle of rotation between them.

Gas stay reinforcement:

It is used to lift up the Tail gate.

They are two types of Gas stay reinforcement is there. That they are

Manual System

Power lift system

Manual system

This mechanism is most used in India cars. It is operated man by his own.

Power Lift System :

It works on the basics of Sensor.

Latch and striker Reinforcement:

Latch placement :

Using the axis of the hinge, a circle is drawn at the middle of the back door and the latch is placed perpendicular to the circle.

Wiper motor reinforcement:

It is small electric motor which is mounted in the rear tail gate. It used to clean the rear wind sheid for clear visibility.

All reinforcement mounting points :

Outer panel:

outer upper panel:

outer inner panel:

Hemming:

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

Hemming is used in assembly as a secondary operation after deep drawing, trimming and flanging operation to join two sheet metal parts(outer and inner ) together.

The accuracy of the hemming operation is very important since it affects the appearance of the surface and surface quality.

Hear hemming tickness -1mm

Corner Relief:

Relief helps to control sheet metal material behaviour and to prevent unwanted deformation during unbend operations. So here I gave two corner reliefs for back door

Back Door Assembly :

Conclusion:

The design of the Back door BIW was completed with the engineering standard and all the reinforcements.