Design of backdoor
Objective :
- Use the provided styling surface to come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcements and embosses.
- The objective of this project is to design a BIW Back Door of a car with an Inner Panel, Outer Panel, and Reinforcements for the Hinges, Gas stay, Wiper Motor, and Latch by following the engineering standards.
Introduction :
Design of back door is also called as the Tail gate. A car back door which is consist of Inner panel, Outer panel. Basically the car parts are made of Steel or Aluminium based on the budget of the car.
Using Aluminium improve the Strength where we can avoid the reinforcements. Aluminium parts are casted and we can very the thickness of the part, because of this avoid or reduce the number of parts as compared to Steel. Only drawback is the cost of aluminium, which is high cast As compared to steel.
Steel Parts are stamped, we cannot vary the thickness of the part because of more number of parts are added. which could increase the weight of the part.
The Backdoor/tailgate is one of the closure commodities in BIW sheet metal design. The backdoor has a lot of components inside and is designed to incorporate them easily. It affects the rear visibility and luggage area.
Total no. of parts in Backdoor are:
- Back door outer panel (upper)
- Back door outer panel (lower)
- Back door inner panel
- Hinge reinforcements
- Gas stay reinforcements
- Latch and striker reinforcements
- Wiper motor reinforcements
Back Door Assembly:
- Inner panel
- outer panel
- hinge and its reinforcement
- wiper motor reinforcement
- latch & stricker and its reinforcement
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.
Materials commonly used in the metal embossing process include:
- Aluminum alloys
- Steel alloys
- Zinc
- Copper
- Galvanized steel
- Brass
- Cold rolled steel
By Using NX Cad
- Outer Panel - 0.75 mm
- Inner Panel - 0.75 mm
- Reinforcements - 1.5 mm
First, we need to create the Tooling direction for the Deep drawing operation. It shows that all the operations like embossing is done by considering this vector direction and it will help in manufacturing the part
Another Emboss is created for Wiper motor mounting.
For positioning the Latch & Stricker, we have to create a trajectory passing through a midpoint of line/ axis of two hinge mounting holes,
Gas Stay Emboss and Reinforcement
Hemming and Hem Relief
Draft Analysis:
.