Design of backdoor

Aim :-

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

Introduction :-

The trunk or boot of a car is the vehicle main storage or cargo compartment often hatch at the rear vehicle. It is also called tailgate, these door can be operated manually or electric powered. In most of the luxury car door electrically operated it involve a very major role during rear cash cases so our design must be obey crash requirement the institute highway safety analyse the different accident and they set a test to rate our car. So these rating depends upon the design of the true and material used flenges, emboss type of joining of inner pannel and outer panel.

Types :-

1. Top Mounted Door

2. Side Mounted Door

3. Bottom Door

Operating Types :-

1. Electrically Operated

2.Gas Stay Powered

Back Door Assembly :-

1. Inner Pannel

2. Outer Pannel

3. Hinge and its reinforcement

4. Wiper motor reinforcement

5. Latch & Stricker and reinforcement

6.Gas stay reinforcement

Difference Between Aluminium And Steel Parts :-

Aluminium Steel

1. Parts are casted Parts are stamped

2. Reinforcement can be neglected Reinforcement are necessary

3. Local thickness can be varied Has only uniform thickness

4. Lighter in weight and less number of Heavier in weight and more numbet of components

Components.

By using of aluminium we can reduce the number of parta and assembly involvement and it castly material.

These are the certain test are done in back door not only back door all components must pass these test but different component have different test because of the functionally.

Sheet Metal Operation :-

1. Deep Drawing

2. First - stage Drawing

3. Redrawing

4. Embossing

5. Hemming

6. Conventional die hemming

7. Roll hemming

8. Blanking

9. Punching

Class A Surface :-

Back door outer and lower case in the class A surface it has to be repaired according to the smoothness, After repair the surface the door divided into two parts and Outer and lower panel.

First we need to create the tooling direction for the direction drawing operation, it show all the operation like embossing is done considering it will help in manufacturing the part.

After we have to sealing flange by offsetting the outer panel to the specific distance. Then we creating dthe back door inner panel flange by offsetting the outer surface at a distance considering sheet thickness and thickening direction.

It created the connecting flange to join the inner panel and sealing flange, Then for windshield panel mounting windshield created and joined with sealing flange.

Assemble the back door with in the vehicle hinges are used open and close the door, For that increase the local area strength we have to design the emboss and provide the appropriate withstand the load acting upon it.

Conclusion :-

The back door outer and inner pannel are design to help of surface along the tooling direction and draft analysis performed well and reinforecement designed and place at appropriate position.