Challenge

Design of backdoor

KKunapuli Sai Teja1 Dec 2022

AIM:

Use the provided styling surface to come up with a back door design, use appropriate design methodologies, and provide the necessary reinforcements and embosses?

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.

Types of doors based on working position,
1.Top Mounted Door
2.Side mounted Door
3.Bottom Door

Back Door Assembly:
tail gate outer upper panel
tail gate outer lower panel
tail gate outer lower panel

Embossing:
Embossing is a metal forming process for producing raised or sunken designs or relief in sheet materials by means of matched male and female roller dies, theoretically with no change in metal thickness or by-passing sheet or a strip of metal between rolls of the desired pattern. Metal sheet is drawn through the male and female roller dies producing a pattern or design on the metal sheet. Depending on the roller dies used, different pattern scan be produced on the metal sheet.

Materials commonly used in the metal embossing process include:
Aluminum alloys
Steel alloys
Zinc
Copper
Galvanized steel
Brass
Cold rolled steel

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. Normally 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 and flanging operations to join two sheet metal parts (outer and inner) together. Typical parts for this type of assembly are hoods, doors, trunk lids and fenders.

There are various types of hemming operations:
1. Conventional die hemming: In conventional die hemming, the flange is folded over the entire length with a hemming tool.
2.Roll hemming: In roll hemming, the hemming roller is guided by an industrial robot to form the flange.

Open Hem: A Hem has a full round feature and a return flange. In open hem bend angle is equal to 180 degrees.
Tear drop Hem: In tear drop hem the bend angle is greater than 180 degrees.
Closed Hem: Hems without any inside radius are called as closed hem. Closed hems are not recommended if the hem geometry is to be painted or if the material used is SST or Aluminium.

Blanking:
Blanking is a cutting operation of a flat metal sheet and the article punched out is knownas blank. Blank is the required product of the operation and the metal left behind isconsidered as a waste.

Punching:
It is similar to blanking only the main difference is that, the hole is the required product andthe material punched out from the hole is considered as a waste.

Back Door Outer Panel:

Below given figure is the dump part of a-surface coming from styling team.

it has so many gaps and faces are not sewed. so, all of them are corrected and sewed.

Back Door Assembly:

In above figure we can see the Hinge axis and Latch and striker rotation circle.

Hemmings are neglected in some places due to the difficulties in A-Surface.

Back Door Upper Panel:

Draft Analysis:

draft analysis performed on oter panel.

Back Door Upper Panel:

Back door inner Panel:

Hinge axis and latch and striker axis are shown with tooling direction.

front view of the inner panel.

force distribution will takes place towrda the reinforcements of hinge and gas stay because of embosses provided.

Gas Stay mounting given below.

Hinge mountings are given below.

Viper mounting is given below.