Design of backdoor

Back Door is called Various Names is trunk (Americans) or boot (British) and Tail Gate of a car. Back Door is Protect main storage or cargo compartment. These doors can be operated manually or electric powered. In most of the luxury cars door is electrically operated. It involves a very major role during rear crash cases. so our design must be Adhere the crash test and safety standard requirements.

Types of doors based on working position,

1. Top Mounted Door
2. Side mounted Door
3. Bottom Door

the back door is operated by two types of comodities

1.electrically operated

2.gas stay powered

the main purpose of these mechanisims is to open the back door without heavy efforts, because the backdoor have different parts and the weight of the back door is high, so we are not able to open the back door manually, so we introduced these two types comodities. and these also decides the premium of the car, mostly the electrically operated used in premium cars.

Back Door Assembly:

• Inner panel
• outer panel
• hinge and its reinforcement
• wiper motor reinforcement
• latch & stricker and its reinforcement
• gas stay reinforcement

the major problem in back door is material selection. mostly in past days steel is used, but it makes a very problems the steel parts have heavy weight,so it reduces the fuel economy, insted of steel presently in high end cars aluminium is used, the main objective of aluminium it have less desnser material and its sutaible for complex shapes, and it also gives the thcikness locally because it it done cating, in case of steel we used deep drawing operation. there are some of the advatanges and disadvantages are there

.

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

these are the certain tests are done in back door,not only back door all components must pass these tests but different components have different test because of the functionaly.

So, that U,Y shape emboss is designed in the Inner Panel of Back Door to strengthen and rigidity

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.

Different types of Sheetmetal operations are done in the Back Door

Deep Drawing:

The metal deep drawing process is an effective method of manufacturing of cups, cans and other similar deep drawing products. The deep drawings having two main categories.

1. First- stage drawing: The blank shape of metal is placed on the die and contact with the punch. When the metal specimen is flat piece of sheet metal used in forming and finish the product. Initially the punch moves in downward direction. The outer rim of blank is subjected to pure radial drawing (drawing toward in vertical axes) between die and blank metal. The metal become a bend and sliding over die and also stretched between die and punch. The metal in vicinity of punch head and contact with it bend and slide over radii and stretch over punch head.
2. Redrawing: The components drawn from first stage again it is redrawn convert into more depth to form a cup shape in the die and punch. The second stage of drawing is called as redrawing.

Hemming:

Hemming is a forming operation in which the edges of the sheet are folded or folded over another part in order to achieve a tight fit. Normally hemming operations are used to connect parts together, to improve the appearance of a part and to reinforce part edges.

In car part production, hemming is used in assembly as a secondary operation after deep drawing, trimming and flanging operations to join two sheet metal parts (outer and inner) together. Typical parts for this type of assembly are hoods, doors, trunk lids and fenders.

There are various types of hemming operations:

1. Conventional die hemming: In conventional die hemming, the flange is folded over the entire length with a hemming tool.
2. Roll hemming: In roll hemming, the hemming roller is guided by an industrial robot to form the flange.

Hinge Reinforcement

Hinge Mounting Area in Inner panel

Gas Stay area Reinforcement

Gas Stay Mounting area in Inner panel

Wiper Motor Mounting area and Reinforcement

Assemble of Stricker in Back Door

• To create Hinge Centre axis and create Point in both LH and RH
• To Draw a line from Hinge LH centre to Hinge Rh Centre
• Then Sketch a trajectory circle from centre point of Hinge axis line
• Then draw tangent line in trajectory circle close to inner panel (stricker mounting area )
• to assemble constraints, align the stricker with help of tangent lines
• then assemble the stricker in inner panel

DRAFT ANALYSIS

Conclusion

Thus the designing of the Back Door or Tail Gate is done as per Designing standard and Manufacturing Techniques.