Design of backdoor

Aim : To design the back door by using the reference surface.

Introduction :

The backdoor of a car is the rearmost part of the vehicle which gives access to the trunk space of the vehicle. The rear door also supports the reinforcements and added weights of the wiper motor, Gas stay, tail lamp, Latch & striker.

Major parts and Reinforcements:

1. Backdoor Outer Panel (Upper)
2. Backdoor Outer Panel (lower)
3. Backdoor Innerpanel
4. Hinge Reinforcements (LH & RH)
5. Gas stay Reinforcement (LH & RH)
6. Latch & striker Reinforcement
7. Wiper Motor Reinforcement

Design Consideration

• Rear Visibility Criteria
• Boot Space/ Luggage area
• Crash analysis
• Bend test, Dent test, Torsion Test & Endurance Test.
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Design of Backdoor outer panel

The outer panel is the styling surface of the back door. other components of the backdoor are designed with reference to the outer panel. It acts as the outer cover and dels with the aesthetics of the car.

Outer panel is divided into two parts. Later these two parts are joined together by spot wellding or seam welding.

1. Upper Outer Panel
2. Lower Outer Panel

1. Upper & Lower Panel is created by using the reference surface given. and hemming is done along with the side relief for ease in tool removal.

=> Relief for the hemming.

=> Outer Lower Panel

=> relief for hemming

Tooling Direction :

Before starting to design inner panel of the back door the tooling direction for deep drawing purpose should be created. styling surface needs to be checked and analyzed it might have irregularities, it must be fixed first.

Design of inner panel

After creating the tooling direction the design of the inner panel will begin where we will first develop an effective sealing flange by checking all the boundraies & by following the shape of the inner panel design.

=> Creating a bottom flange

=> creating embosses for strengthening the part and for force distribution.

=> Creating embosing for hinge and gas stay support

Gas stay

Making the tarjectory for the Latch palcement

=> Now after making mirror of the geometry we can make the embossing for latch.

as we finished all the designing points we can finally thicken the sheet. the final part we appear as shown below

=> now making reinforcements to give strength & support to the areas where parts are going to join with other parts.

Reinforcements of Hinge connection,Gas stay & Latch and striker.

=> Draft analysis for the parts.

Inner Panel

Outer panel