Design of backdoor

REPORT- BACK DOOR DESIGN

1. OBJECTIVE- 
   • To design the back door parts (outer panel upper & lower, inner panel, sealing flange, mounts, reinforcements and mastig flange.
   • Draft analysis of inner panel ad assemble the whole back door.
     
     
2. BACK DOOR PARTS-
   1. OUTER PANEL UPPER-Outer panel upper is the upper par of outer panel which consists the wind shield and wind shield mount and tail light mount. and the hemming region for upper side of inner panel. I designed this with proper thickness of 0.75 mm from given A surface.
      
      A surface should be modified because I faced issues when I was doing the thickening.
      
      
   2. OUTER PANEL LOWER- It is a separate part of outer panel. I did only the hemming and the thickening.
      
      
      
   3. INNER PANEL-Inner panel is the main part which gives the strength to the back door. The sealing flange is created in the inner panel. I designed the sealing flange, embosses, the mastig mounting flanges, the hinge mountings, latch and stricker, the gas stay mountings and the wiper mouting in the inner panel. All mountings should be done in the inner panel.
      
      
      
      1. Sealing Flange-Sealing flange basically designed to do air and water tight to the back door. When the door closes the sealing flange press the sealing rubber and get the back door water and air tight.
         
         In the above pictures the 1st one we can see the roof outer panel has a flange which is the seal mounting flange..at the end this is the sealing rubber, and when the door will be closed the sealing flange pressed the rubber parallel and air and water tight will be occurred.
      2. Mastig mount flange-mastigs flange is designed for mounting the inner panel with the outer panel. As we know if we spot weld the parts the the welding mark will be occurred in the A surface so we have to avoid that and use the mastigs for mountings.
         
         Here the the cutout length should be greater than the flange height+folded part length, because for manufacturing the flange will be created from a cutout sheet. First the sheet will be cut and then the flange will be folded.
      3. Hinge mount-Hinge mount I created at the top of the inner panel. Hinge mount is used to mount the hinge for closing and opening the door.
         
      4. Gas Stay mounting-Gasstay is a hydraulic system which is fitted at the side portion of inner pannel. It is basically used to open the and close the door with less power and more smoothness.
         
         I did two gas stays mountings in the two sides of the innr panel.
      5. Latch and Stricker-Lacth and stricker is for locking the back door with the car body. The latch should be perpendicular to the the circle which is the closing and opening radius of the car  back door.
         
         Latch and Stricker mount.
      6. Wiper mounting-Wiper mounting is basically used to mount the wiper motor mount. This is created near to the wind shield mount.
         
         
         
      7. Hemming-Hemming is one of the joining process which is used to join the inner panel to the outer panel, as I told that spot welding should not be done so the hemming process is being taken. After hemming the mastigs are applied between the hemming and the inner panel.
         
         
         The gap should be 0.2 mm as in the above picture.
         
         
      8. Reinforcement-Reinforcement is used to give strength to the part mounting areas or in the corner. It is nothing but adding some material to the particular parts where reinforcement is needed. I did upper corner reinforcements, hinge reinforcement, gastay reinforcement, lower corner reinforcement, latch and striker mounting reinforcement, wiper motor mounting reinforcement. And I  did these as different parts.
         
         Hinge assembly reinforcement (red one).
         
         Gas stay reinforcement blue one.
         
         Upper corner reinforcement yellow one.
         
         Wiper motor assembly reinforcement.
         
         Latch and Stricker mounting reinforcement.
         
         Lower corner reinforcement.
3. DRAFT ANALYSIS-Draft analysis is for checking the draft angle if it is correct or not. As we know The draft angle should be min 7 degree for the sheet metal. As the parts are manufactured using stamping or deep drawing so the draft should be min of 7 degrees of angle. Here the inner panel will be manufactured with stamping or deep drawing, so I did draft analysis for the inner panel.
   
   The green means the draft angle is above 7 degree then it is OK.. If it seems to be in red then it was not ok.
   
   
4. CONCLUSION- The A surface of outer upper need to be modified as the thickening gave error.