Design of backdoor

OBJECTIVE :To create a backdoor assmbley with given backdoor panel.

INTRO:

Backdoor/Tailgate is a door or a combination of 2door that is used to secure the commodities of passengers in the rear of the vehicle. it also acts as a protection to rear end colission.

Most commonly found are top mount ,side mount and botom mount.

Topmount backdoor

Sidemount cardoor

Barndoor

Bottom mount

1967 ford country squire6

Gas stay

Latch assymbley

kia

Hinge

exploded view of backdoor

Aim

• Refine the given panel
• create the inner pannel with requird strengh and coutouts
• create re-enforcement for the hing,latch,wipermotor,and gasstay

Given panel

Initially there were a few disjoint surface , all the disjoint surface were corrected, uneven surface where smoothen out, and sharp edges were rounded.

The provided panel was split in two, upper outerpanel and lower outerpannel.

Outer pannel upper

The above images are screenshots shows upper outterpannel. Thickened inward by 0.75mm

Lower outer pannel

The above images are screenshots shows lower outterpannel.Thickened inward by 0.75mm

The upper and lower pannels are joined by brassing. or spotwelding.

Inner pannel

The innerpannel is developed from the given outer pannel. To add strength embosses are created.

A "Y" or "V" shape emmboss is created to divet the sterss to the outer side of the body. this increses the saftey of the rear passenger.

also the stress caused by clossing the door harshly..

also center regioon is cut and bend in such a way that mastic glue can be used betwwin that surface and the outer panel,this would increase the strength and reduce ratling noise.

Hinge reinforcement

hinge reinforcemet is placed on the opposite side of the panel where the hinge is attached. in such a way that the inner pannel is sandwiched between the hinge and hinge reenforcement. This helps in incrreasing strength and stress distibution.

Gas stay suppoert

strut reinforcemet is placed on the opposite side of the panel where the gas stay is attached. in such a way that the inner pannel is sandwiched between the gas stay and the reenforcement as it helps in incrreasing strength and stress distibution.

Wiper motor reenforcement

wiper motor reinforcemet is placed on the opposite side of the panel where the hinge is attached. in such a way that the inner pannel is sandwiched between the wiper motor and wiper motor reenforcement. This helps in incrreasing strength and stress distibution.

Latch reenforcement

latch position is determined by taking the mid line of the hinges as the axis of rotation ,. and latch is placed tangential to the rotation.

Results:

The zip file has been attached.