Challenge

Design of backdoor

UUmar Sha2 Sept 2022

AIM:

To design car back door from given styling surface data under given design rules and regulations.

INTRODUCTION:

A door is a hinged part which is used for entry and exit vehicles . Back doors are one of the type doors of the vehicle which are located next to the passenger seat which provides access to the luggage compartment. In most of the cars , these back doors are operated with the help of gas stay which in turn reduces the effort required to lift open the door. Some luxury cars have powered backdoor which in turn is driven by an electric motor.

Types of the back door

Top - Mounted:

This type of back doors is used in a station wagon , pickup truck and some of the sport utility vehicles.Todays modern cars use top-mounted tailgating systems which are both powered and also gas stay supported . These top mounted tailgates provide greater rear visibility compared to side-mounted or bar doors which have center pillars in it.

Side Mounted Doors:

As the name signifies side mounted doors are the one which is used in the van type MPVs,SUVs, pickup truck vehicles.These side mounted doors or barn doors are a lot easier compared to top mounted doors.

Bottom/Split Type:

This bottom type or splt type backdoor system are used in the car type such as estate type car , pickup trucks and some luxury SUVs. These are the most convenient type of back door in which the bottom split is used as a support or even as a table for the tour going people.

Types of Mechanisms for Rear Door:

Gas Stays Type.
Powered lift System.

Gas Stays Type:

Powered Lift System:

DIFFERENT METHODS OF MANUFACTURING FOR BACK DOOR:

Blanking:

Blanking is a metal fabricating process during which a metal workpieces is removed from the primary metal strip or sheet when it is punched . The control of the quality by the punch and die clearance . The ability to produce holes of varying shapes-quickly.

Deep Drawing:

Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch, It is thus a shape transformation process with material retention. the process is considered "deep" drawing when the depth of the drawn part exceeds its diameter.

Trimming:

Trimming is a manufacturing process that is used as a finishing operation for forged parts in order to remove flash. Most often it is desirble to perform this operation while the work is still hot for maximum efficiency , therefore it is usually incorporated into the larger production process.

Hemming:

Hemming is a sheet metal forming process in which sheets are joined by bending it usually to 180degree. Automotive body panels and automotive parts such as deck-lids,trunk-lids,doors,hoods and tailgates are formed by hemming process . Hemming is a forming operation in which the edges of the sheet are folded over another part in order to achieve a tight fit .

Design Consideration:

Rear visibility
Hinges and gas stays
Fit and clearances
Boot spaces and accesibility

Procedure:

BACK DOOR ASSEMBLY:

Inner panel
Outer panel
hinge Reinforcement
Gas stay reinforcement
Wiper motor reinforcement
Latch , striker reinforcement

Inner Panel:

The inner door panel is a component which is used to strengethening the door assembly and it is one of the most important components on which all accessories are mounted like hinges,glass guide channel , moulded trim ,latch etc. The possible method is integration method.In the integration method the part is stamped out of a single blank.

Inner panel Embose

Outer panel:

1.Upper outer panel.

2.Lower outer panel.

1. Upper outer panel:

2.Lower outer panel:

DESIGN OF RE-INFORCEMENTS:

Reinforcements basically strengths or increases the mechanical properties of the material. The hinge are provided so as to increases the strength during bolting.

The different types of reinforcements used here are ,