Design of backdoor

AIM :  To design the back door of car 

OBJECTIVE :

• To create design of backdoor of car using CAD software .
• To create necessary reinforcement.
• To carryout draft analysis .
• To make report o it.

INTRODUCTION :

• Backdoor is located at the rear side of  a car and give access for the boot space to store luggage , spare wheel etc.
• Backdoor is also called tail gate . A car back door is consisit of inner panel , outer panel and various reinforcement .
• Material used for the backdoor are steel and alumimium .

 

Types of door :

1) Top mounted door .

2) Side mounted door .

3) Bottom mounted door .

4) mannually operated .

5) Gas stay powered.

6) Electric powered.

Material selection :

Aluminium:

• Aluminium improve the strength so we can avoid the reinforcement .
• Aluminium part rare casted .
• Its thickness can be varried .
• It has high cost .

Steel :

• While using seel we need to do reinforcement .
• Steel parts are stamped .
• So it has uniform thickness .
• It is cheaper than aluminium.

Manufacturing process :

Deep drawing :

• The deep drawing process is an effective method of manuacturing of automotive hood , door , cups , cans  etc.

Embosing :

• It is a metal forming process for producing raised design or relief in sheet metal by means of matched male and female roller dies .

 

Hemming :

• It is also a forming operation in which the edge of the sheet are folded over another part in order to achieve a tight fit .
• It is used to connect parts together .
• It is done as secondary operation after deep drawing  ,trimming  and flanging operation to join two sheet metal parts together .

Blanking :

• It is a cutting operation of a flat metal sheet and the punch out is known as blank . 

Punching :

• In this process the hole is required product and the material puncheed out from the hole is consider as waste .

 

Component used in Back door are :

• Outer panel upper.
• Outer panel lower.
• Inner panel .
• Latch and stricker reinforcement.
• Gas stay reinforcement.
• Hinge reinforcement.
• Wiper motor reinforcement .

Design procedure :

• The styling surface is given to us .
• We have to first repair the surface.

• Then we have created tooling direction .
• It is used during draft analysis.

•  Here we have created sealing flang.
• The part that sits on the rubber fil when door is closed and prevent the water from coming inside car.

• Now connecting flange is made .

•  Then after windshield is made.

• Mastic region is created having distance of 3.5 .
• It is used to join innner panel with outer panel.
• Emboss is done to strengh the part.
• Various cutouts are made to reduce the weight of the component.

•  this is the final view of inner panel.

• Outer upper panel:

• Outter lower panel :

Reinforcements :

•  Hinge reinforcements 

• Wiper motor reinforcement:

• Gas stay reinforcement 

LAtch and striker reinforcement :

Hemming :

• Here hemming is done by ofseting outer pannel to (0.75*3 + 0.2*2) 6.25 mm .

Final image of inner panel :

Final assembly :

Draft analysis:

• As a sheet metal part are generated from press tools or forming tools , it requires some space to come back to their initial position .
• So it is necessary to provide draft angle , so that part can be easily removed .
• Here we have done draft analysis in NX.
• We have giving vector as tooling direction .
• As shown below , we can see that there is green region which shows that it can be easily drawnout from that.

Conclusion :

• He have created CAD assembly of car door.
• Done require reinforcement .
• We have done draft analysis .