Challenge

Design of backdoor

AAkshay Kumar1 Jul 2022

AIM - To design car back door panel from given surface A data under design rules regulation.

BACK DOOR ASEEMBLY

Inner panel
outer panel upper
outer panel lower
hinge and reinforcement
wiper motoe reinforcement
latch and striker its reinforcement
gas stay reinforcement

OUTER PANEL - 0.75mm

INNER PANEL - 0.75mm

REINFORCEMENT - 1.5mm

A back door of a car also known as taail gate. which normally serves the purpose of covering the car from the rear end but there are more function that come with it which has to be considered while making a design of the same like rear visibility criteria and boot space .this part is usually designed keeping the master section of the rear roof rail because of the sealent flange and also various other consideration as it is also in contact with the side body of the car.

Repairing input

The first step is to organize the input skin data as upper outer surface and lower outer face .but before that we have to check for any irregularities in the surface and repair and sew together.

Sealing flange -

Usually we will take refrence from the roof master section for the sealent flange ,but as it was not available we have made entire sealing flange in this model .the space occupied by the rubber sealent is usually in the range of 25 mm is the open condition so we maintained that distance between ineer panel and the sealing flange is made ,we make a connecting flange on both side of it end complete the flange to be joined with inner panel.

INNER PANEL -

The shape of inner panel is same as that of the outer panel up to the windshield surface .after that we have to make surface for various components asuc as latch and striker motor etc.so we make a proper curved surface at the lower side so that we avoid links at the mirroring plane .once of the main body is ready,we have to decide the design the following things .

Mastic region: we have to design it as abig one at a single region in the centre or two small regions.

Emboss - We have to crate to emboss to diverge the force.
Latch and striker - this will mounted on the side of the inner panel but we must make a similar cutout on both the sides keeping centre of gravity in mind.
MAterial out cuts - we should remove the material from new region to reduce weight of the inner panel.

Few mountigs which have to keep mind and make reinforcement-

HINGES - The model is such as that the back doorwill be mounted on the roof so the hinges mounting emboss has to be provided accordingly on the top some where .

GAS STAY - The back door will have gas stay method for openingand keeping it open thus this mounting emboss will be needed somewhere on the side.

WIPER MOTOR - The back door will also have a wiper whose motor his to be mounted somewhereas only single wiper will be present it is common give to give this in the middle near winlshield.

LATCH AND STRIKER -IT is the one which lock and unlock the back door rotates and as the back door rotates on the hinge axis must be presenton that patch only.

once all these design is made we move on to make the mirrior of the model in order to make it complete .after mirrioring the inner panel a handle mounting space is provided .after the detailing work is done it is thicken of 0.75mm.

HEMMING - Hemming is forming operation in which the edges of the sheet are folded over another part in order to achieve a tight fit.normally hemming operation are used to connect parts togrtherto imrove the apperance of apart and to reinforcementb part edges.

REINFORCEMENT

A Mentioned for local strength reinforcement are usually provided . instead of making the whole panel off a thicker sheet a thinner sheet with local reinforcement.thiknen is 1.5 mm.