Challenge

Design of backdoor

AAbdulla S5 Sept 2022

AIM:

To design the back door of the carr and make the inner panel for the back door and also design the necessary

INTRODUCTION

The trunk (North American English) or boot (British English) of a car is the vehicle's main storage or cargo compartment, often a hatch at the rear of the vehicle. It is also called a tailgate.These doors can be operated manually or electric powered. In most of the luxury cars door is electrically operated. Ii involves a very major role during rear crash cases. so our design must be obey crash requirements. the institute of highway saftey analyse the diffrent accidents and they set a test to rate our car. so these rating depends uopn the design of the trunk and material used, flenges, embosses, type of joining of inner panel and outer panel etc.

Parts of back door:

Outer panel
Outer panel lower
Inner panel
Hinge reinforcement
Latch and striker reinforcement
Hinge reinforcement
Gas stay reinforcement

Types of back door

Top mounted
Bottom mounted
Side mounted

Material selection:

by using of aluminium we can reduce the number of parts and assembly involvement. and it is castly material.

Force dissipation:

The major criteria in designing the back door or any BIW part is the force dissipation during an impact or a colloision. Hence studies are being done inorder to dissipate the force on the sides and avoiding it reach the inner cabin of the car so that possible damage of imapct inside the car is reduced. Hence inorder to do that the V or Y embosses are created on the inner panel so that the force gets transmitted on to the sides instead reaching it on the cabin. This is one of the main criterias in back door design.

Hemming:

Hemming is the metelworking process in which a sheet metal edge is rolled into itself.The outter surface of the panel is rolled 2 or 3 times over the inner panel.In first roll the panel is bent slinghtly,and in the second roll the shhet matel is rolled even more and in the last roll it completely fits or covered the inner panel.There must be a 0.2mm gap between outter and inner pannel in both upper and lower side.

various types of hemming are

Embossing:

Embossing is a metal forming process for producing raised or sunken designs or relief in sheet materials by means of matched male and female roller dies, theoretically with no change in metal thickness or by-passing sheet or a strip of metal between rolls of the desired pattern. Metal sheet is drawn through the male and female roller dies producing a pattern or design on the metal sheet. Depending on the roller dies used, different patterns can be produced on the metal sheet