Design of backdoor

ANSWERS:

OBJECTIVE
To design the back door assembly of a car using the given skin data and also design the back door inner panel, hinge reinforcement, gas-stay reinforcement, wiper motor reinforcement, latch, and striker reinforcement using NX-cad software.

INTRODUCTION
The back door is used to access the boot space of the car. The back door assembly consists of an outer panel and an inner panel. The outer panel and inner panel are joined by hemming and mastic sealant. The inner panel is used to strengthen the outer panel by embossing the inner panel surface. The inner panel consists of hinge reinforcement,gas-stay reinforcement, wiper motor reinforcement, and latch reinforcement.
The hinge is used to connect between the roof and inner panel for opening and closing of the back door. The gas-stay is used to support and maintain the position of the back door while in the opened condition. The wiper motor is used to clean the glass on the back door. The latch is used to lock the back door.

Components of back door assembly
a. Outer panel
b. Inner panel
c. Hinge reinforcement
d. Gas-stay reinforcement
e. Wiper motor reinforcement
f. Latch and striker reinforcement

Outer panel
The outer panel is the styling surface. the thickness of the outer panel is 0.75mm. The outer panel and inner panel are joined by the hemming surface.

                            

Inner panel
The inner panel consists of embosses these embosses are providing strength to the inner panel during impact. The inner panel also consists of a mastic support region which is used to put mastic sealant between the outer and inner panel surface for preventing vibration.

          

Hinge reinforcement
Hinges are used to closing and opening of the back door. Hinges are clamped between the roof inner panel surface and the back door inner panel surface. They are having a limited angle of rotation between the roof and back door. The reinforcement surface gives extra strength to the hinge clamping surface.

                                   

                                         

Gas-stay reinforcement
Gas- stay are used to maintain and support the position of the back door and the reinforcement give more strength to the gas-stay clamping surface.
There are two types of gas-stay manual system and power lift system. The Manual system is operated with the help of manpower. The power lift system is operated with the help of sensors and motors.

   

Latch reinforcement
The latch is used as a locking mechanism for the back door. The latch reinforcement gives extra strength to the latch clamping surface.

                     

Wiper motor reinforcement
The wiper motor is a small electric motor clamped on the back door. It is used to clean the rear windshield for clear visibility. 

                    

Corner relief
The corner relief helps to control sheet metal from unwanted deformation during unbend operation.

  

  

Tooling direction
The tooling direction is created for deep drawing purpose before designing the inner panel.

                               

Latch and striker position

                               

Mastic sealant
The mastic sealant is used to fix the inner panel reduce the vibration and strength to the back door.

                          

Hemming
Hemming is the process of joining the inner panel and outer panel of the back door. Set of rollers roll the outer panel surface to get hemming surface. The gap between the outer panel and inner panel is filled with sealants to make the joint waterproof.

                                       

Conclusion
Thus the parts of the back door were designed from the given styling surface and all the reinforcements are designed and assembled by using the NX-cad.