Design of backdoor

OBJECTIVE:

1.the styling surfaceis given and by using this styling surface, develop a back door using appropriate design methodologies.

2. The objective of this project is to design a BIW Back Door of a car
3. And create an Inner Panel , Outer Panel , and Reinforcements for the Hinges, Gas stay, Wiper Motor, and Latch by following the engineering standards.
4. The Inner Panel must be subjected to Draft Analysis for verifying whether it satisfies the Deep Drawing requirements for the tooling direction created in the design.

SOFTWARE USED:

Siemens NX CAD

PARTS OF BACKDOOR AND REINFORCEMENTS

1. Backdoor Outer Panel (Upper)
2. Backdoor Outer Panel (Lower)
3. Backdoor Inner Panel
4. Hinge Reinforcements (LH & RH)
5. Gas-Stay Reinforcements (LH & RH)
6. Latch and Striker Reinforcement
7. Wiper motor Reinforcement

DESIIGN OF BACKDOOR OUTER PANEL

The Outer Panel is the styling surface of the back door. Other components of the backdoor are designed with reference to the outer panel. It acts as the outer cover and deals with the aesthetics of the car.

In this design outer panel is divided into two parts

1. Outer Upper Panel
2. Outer Lower Panel

OUTER UPPER PANEL:

The outer upper panel extracted from a styling surface.

The thickness is altered for the required design with surface tools of NX CAD.

Hemming is provided with the corner relief.

Outer Lower Panel:

The Outer Upper Panel Extracted from a styling surface.

The panel is altered for the required design with the surface tools of NX CAD

The thickness provided for the outer panel is 0.75 mm

Hemming is provided with the corner relief.

Tooling Direction:

• Before starting to design the inner panel of the back door the tooling direction for Deep Drawing purpose should be created.
• Then the styling surface needs to be checked and analyzed since it might have irregularities, hence it must be fixed first.
• Then the back door was designed using the top-down approach.
• 

DESIGN OF BACKDOOR INNER PANEL:

The Inner Panel Extracted from a styling surface.

The panel is altered for the required design with the surface tools of NX CAD

The thickness provided for the outer panel is 0.75 mm

MASTIC SEALANT:

The mastic sealant is used to fix the inner panel with the outer panel which increases the NVH factor and stiffness of the back door.

HEMMING:

Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming is the process in which the edge is rolled flush to itself.

• The outer panel was designed as two separate parts named as outer panel upper and outer panel lower.
• After designing the outer panel the Hemming was created by offsetting the surface with the help of face blend and swept surface.
• The two separate outer panels will be joined using Blanking
• 

corner relief:

Provide draft analysis:

After that we check whether the inner panel that we have designed can be deep drawn. We use Draft analysis for this purpose. It is based on different colour zones that indicate whether the part can be manufactured or not.\

so all the surface are green color of the inner panel

Some reinforcement images are mentioned below

That is for gas stay, wiper, hinge, striker reinforcement.

so the backdoor is successfully created

thankyou......