Design of backdoor

BACK DOOR

Aim:

To design a car back door inner panel with a proper draft angle for manufacturability and its necessary reinforcements.

Introduction:

The car door is considered a door when it has a hinge. The back door is on the back side of the door it is also called the trunk, the boot of a car, the cargo compartment, and the storage compartment. It is also called a tailgate. Inside a back door, it has a wiper, wiper motor, tail light, number plate light, and striker. It involves a very major role during rear crash cases so it should minimize the injuries during a collision.

The backdoor consists of:

• Backdoor inner panel
• Back door outer panel upper
• Back door outer panel lower
• Hinge reinforcements
• Gas-stay reinforcements
• Striker reinforcement
• Wiper motor reinforcement

DESIGN

Given skin, data is modified to make smooth edges and curved sharp corner

Inner panel

Tooling axis

Design Process

Embosses are created to increase strength and provided flat embosses for the hinge, gas stay, wiper, and striker, in this area reinforcement is also provided to increase strength.

Cutouts are given to reduce the weight of the inner panel and easy access to other components

Emboss is given in the shape of a “U” to distribute the impact force during the collision.

This flange is created to connect at the center of the back door outer panel using mastic glue which strengthens the outer panel and also for NVH reduction purposes.

Outer panel

Hemming

It is a process to hold the inner and outer panels with mastic sealants instead of spot welding because spot welding will affect the aesthetic of the car.

Corner relief

Reinforcements:

Reinforcements are provided to strengthen the component at the functioning areas like the hinge, gas-stay, and latch & striker.

All the reinforcements are 1.5 mm thick.

Hinge reinforcements

gas stay reinforcements

striker reinforcement

wiper reinforcement

ANALYSIS

Hinge axis and striker position study:

The hinge axis is a center, with that center trajectory circle created and the striker should be perpendicular.

striker

latch

Draft analysis

CONCLUSION:

The design of the backdoor BIW was completed with all the necessary requirements.