Design of backdoor

Initially the tooling axis was made for manufacturing components through deep drawing processes. After the creation of tooling axis the upper and lower door were created.

Backdoor upper part

Backdoor upper part is extracted and altering the surface of class A as shown in Figure and their draft analysis indicates that there is no under cut are present in the backdoor upper part.

Back door lower part

Similarly, the back door lower part is extracted from the class A surface and their daft analysis showed that there is no undercut part

Back door inner part

To improve the strength of the back door, the emboss and other cut out were created and also Latch and Stricker, Hinge reinforcement, wiper motor reinforcement and gas stay emboss as shown in the figure are made in the inner panel. The draft analysis is done and the green colour indicates that surface have an draft angle of greater than 7.

Hinge reinforcement

Latch and striker emboss

Latch and striker is used to open and close the back door. To increase the strength of the components the emboss are incorporated the in the design as shown in the figure. The draft analysis studies indicates that there is no under cut in the material

Wiper motor reinforcement

Mastic filling

The mastic filling is used to connect inner and outer door panel and also it reduce the vibration of the panel drastically.

The hemming process is done between inner and outer panel with an clearance of 0.2 mm and hemming relief was created at each corner

Back door design