Design of backdoor
Aim :
To develop the car Backdoor(Tail gate) with the reference of given skin data as per engineering standarad by using NX12
Back Door :
The Back door is typically hinged, but sometimes attached by other mechanisms such as tracks, in front of an opening which is used for entering and exiting a vehicle.
A vehicle door can be opened to provide access to the opening, or closed to secure it. These doors can be opened manually, or powered electronically. Powered doors are usually found on minivans, high end cars, or modified cars.
Different Sheetmetal processes used for manufacturing 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.
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.
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
The inner & outer panels are joined by the process of hemming.
Hemming is a forming operation in which the edges of the sheet are folded over other parts in order to achieve a tight fit. Usually, 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 & flanging operations to join two sheet metal parts together. Typical parts for this type of assembly are hoods, doors, trunk lids & fenders.
The accuracy of the hemming operation is very important since it affects the appearance of the surface & surface quality. Material deformations, which occur while the hemming process, can lead to dimensional variations & other defects in parts. Typical hemming defects are splits and wrinkles in the flange, material overlaps in the corner areas. So it is very important to use simulation software tools to better understand the hemming process and minimize the number of “trial & error” during the tryout.
There are different types of hemming operations:
Conventional die hemming
In conventional die hemming, the flange is folded over the total length with a hemming tool.
Roll Hemming
In roll hemming, the hemming roller is guided by an industrial robot to make the flange.
Types of Back Door :
Top Mounted
Side Mounted
Bootom Mounted
Top Mounted Back Doors :
Side Mounted Back Door :
Bottom Mounted Back Door :
Design Consideration :
Visibility Criteria
Latch and Stricker Position
Hing Position
Gas Stay Position
Space Avalibility
Drain Holes
Hemming and Relief area's
Components of Back Door :
The Components of Back Door as follows,
Inner Panel
Outer Panel
Hing Reinforcement
Latch and Stricker Reinforcement
Gas stay Reinforcement
Wiper motor Reinforcement
Inner Panel :
Hinge Reinforcement :
Hinges are the essential, that allows doors to pivot on one edge as they open and close. They are found on virtually all doors. It is a mechanical bearing that connects two solid objects, typically allowing only a limited angle of rotation between them.
Gas stay Reinforcement :
It is used to lift up the Tail gate.
There are two types of Gas stay reinforcement is there. That they are
Manual System
Power Lift System
Manual System :
This mechanism is most used in Indian cars. It is operated man by his own.
Power Lift System :
It works on the basics of Sensor.
Latch Reinforcement :
A latch is not the same as the locking mechanism of a door or window, although often they are found together in the same product. Latches range in complexity from flexible one-piece flat springs of metal or plastic, such as are used to keep blow molded plastic power tool cases closed, to multi-point cammed latches used to keep large doors closed.
Wiper motor Reinforcement :
It is small electric motor which is mounted in the rear Tail gate. It used to clean the rear wind shied for clear visibility.
Outer Panel :
Corner Relief:
Relief helps to control sheet metal material behaviour and to prevent unwanted deformation during unbend operations. So here we give two corner relief for Back door.
Hemming :
Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming is the process in which the edge is rolled flush to itself, while a seam joins the edges of two materials.
CONCLUSION:
Thus the Body In the White Back Door of a car was designed by following the engineering standards & also the deep drawing requirements consideration.