Design of backdoor
BACK DOOR:-
The Back door of a car is a component which hinges at the back of the car to cover the boot space or luggage area, it has back lights/ Tail lamps and Braking lights which is termed as "Third brake light" mounts on it, rear windshield fixes between inner and outer panel, in some back door spare wheel can be mounted on it, sometimes car registration number plate mounts on it and it gives a complete closed design to the car.
=>Back door is an automobile sheet metal component.
=>It covers the rear part of the vehicle and rear visibility.
=>Backdoor is the hinged door at the rear part of the vehicle and can be moved up or down. It also accesses the boot space or trunk.
=>The car follows FMVSS(federal Motor Vehicle Saftey Standards) regulations for rear visibility criteria.
Design Considerations for a Back Door:-
=>Rear Visibility for Functionality and Safety.
=>Boot Space and Accessibility.
=>Type of Backdoor Opening (For individual vehicle requirement).
=>Fixing and Support Structures like Hinges and Gas stays.
=>Mounts for Wiper Motor, Back Lights/Tail Lamps and Other Wiring loops.
=>Fit and Clearance (For Assembly and Aesthetically looks).
=>Strength Of Backdoor (Require in collision).
Back door consists of
=>Outer panel
=>Inner panel
=>Hinge mounting bracket
=>Latch reinforcement.
=>Wiper motor mounting
=>Gas stay mountings and reinforcements
Outer pannel:-
=>The outer panel act as the covering layer for the inner panel.
=>It also prevents the entry of dust particles, and chips into the inner panel.
=>It provides the aesthetic look of the car.
Inner pannel:-
=>Design the inner panel with effective design methodologies for more reliability and prevent damage during crashes.
=>Inner panel is the heavier part.
Designing methodologies of inner pannel:-
=>Deep drawing
=>Embossing
=>Lancing
DEEP DRAWING:-
It is a sheet forming operation, in which the sheet is placed over the die opening and is pushed by punch into the opening. The sheet is held flat on the die surface by using a blank holder.
EMBOSSING:-
=>Embossing comes under the deep drawing process.
=>It is internally created on the inner panel and imparts a design on a surface so that it stands out.
=>To create a raised surface, two dies come in contact with the surface of sheet metal under high pressure.
LANCING:-
It is a process of creating a partial cut in the sheet. So that no material is removed. The material is left attached to bend and form a shape.
Sealing flange:-
=>Sealing flange is designed with the inner panel.
=>It plays a role in increasing door closing effort and isolating the passenger compartment from water and wind noise.
=>It also resists vibration during dynamic conditions.
Hinge mountings:-
=>The door hinges for automobiles are used to hold the door in a predefined axis during closing and opening the operation.
=>The hinge mounting brackets are designed to keep the hinges.
Latch mountings:-
=>It is located inside the back door assembly and engages with the door striker.
=>The main use of a latch is to prevent unauthorized entry to the vehicle.
Wiper motor emboss&mountings:-
Gas stay mountings:
=>It will be mounted to the existing holes of gas stay mountings.
=>It takes minimal effort to lift the back door.
Draft Analysis:-
=>Draft Analysis is done to analyze the draft angle. This allows us to verify whether the product will be easily removed from the tool.
=>When designing a product it needs to be slightly angled so that the tool can be pulled away from the part easily, without deformation or damage. This slight angle is called draft.
=>Minimum Draft of 7 Degrees provided for easy manufacturing of sheet metal
Latch & Trajectory:-
=>The door is opened and closed along the trajectory path without any obstacles.
=>Hinge axis is taken as a center to draw the circle at the middle of the backdoor and is placed perpendicular to the circle.
Various tests are performed by the back door because of to check the strength,durability,quality it will helps to any modifications
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. Hemming is a technology used in the automotive industry to join inner and outer closure pannals together (hood, side doors, tailgates, etc.).
It is the process of bending/folding the flange of the outer panel over the inner one.
The accuracy of the operation significantly affects the appearance of the car’s outer surfaces and is therefore a critical factor in the final quality of a finished vehicle.
FINAL ASSEMBLY:-
