Design of backdoor

OBJECTIVE:

DESIGN THE BACK DOOR WITH THE HELP OF THE STYLING SURFACE PROVIDED USING PROPER METHODOLOGY AND PROVIDE THE NECCESSARY REINFORCEMENT AND THE EMBOSSES. 

INTRODUCTION:

BACKDOOR ALSO CALLED AS TAIL GATE.

LIKE WHAT WE SEE IN HOOD AND SIDE DOOR ,BACK DOOR /TAIL GATE IS ALSO A SWINGING COMMODITY ; A CLOSURE COMMODITY.

LIKE WE DID FOR HOOD AND WHAT WE DID FOR SIDE DOORS WE DO SAME FOR THE BACKDOOR DESIGN ALSO.WE FIRST DECIDE THE HINGE AXIS AND THEN THE LATCH AND STRIKER POINT .WE JOIN THE TRAJECTORY TO DECIDE THE MOTION OF THE BACK DOOR AND TO FIND OUT THE DESIGN DOOR . 

ALSO HERE LIKE SIDE DOOR THE EILING FLANGE IS ALSO IMPORTANT .SO WE PREPARE THE MASTER ON THE TOP ,BOTTOM AND HINGE AREA TOP AND WE DEVELOP THE SEILING SURFACE LIKE THAT CORNERS,SINCE GAS STAY IS USED HERRE WE USE GAS STAY TOP MOUNTING ,BOTTOM MOUNTING POINT ,ALSO TO DEVELOP THE SEALING FLANGES.

WITH RESPECT TO THE STYLING WE POSITION OUR MASTER AND WE DEVELOP THE SEALING SURFACE AND THEN WE CONTINUE THE CONSTRUCTION.

IS THAT ALONG SUFFICIENT FOR BACKDOOR ,NO OTHIS BACKDOOR /TAIL GATE ALSO TAKE THE RESPONSIBILITY FOR REAR VISIBILITY AND THE LUGGAGE AREA.

MORE THINNER THE OUTER PANEL ,MORE THE LUGGAGE AREA WE GET ,SO WE CANT MAKE IT STRAIGHT ,BECAUSE WE HAVE TO PROVIDE STRENGTH TO THE BACKDOOR.

WE NEED SOME SPACE TO ACCOMODATE LATCH AND STRIKER AND TO ACCOMODATE THE WIPER MOTOE ,SO I WILL HAVE DEEPNESS HERE BUT HOW MUCH THE DEEPNESS IS A FACTOR, ALSO THE IS HTE REGION WHERE HE HAVE THIS SEALING AND SEATING IS AGAIN A SIMILIAR SITUATION LIKE WHAT WE SEE ON SIDE DOOR .

IT IS IN CONTACT WITH THE REAR FLOOR IN THE BOTTOM ,AND ROOF IN THE TOP AND BODY SIDE SO ,WE ALSO CONTACT WITH ALL THE ENGINEERS BECAUSE THEE SEALING IS INPUT FOR BODY SIDE PEOPLE ,ROOF SIDE AND ALSO INPUT FOR THE ROOF PEOPLE.

WE WILL HAVE A RUBBER ON THE REAR ROOF END AND THE BACK DOOR WILL SIT ON THE RUBBER ,THE RUBBER IS IN THE COMPRESSED POSITION WHEN THE DOOR IS CLOSED .

WHY NOT WE PREPARE THE BACK DOOR BY THE ALUMINIUM AND IF IT IS MADE BY ALUMINIUM ,WHAT ADVANTAGE WE GET,INNER PANEL OF THE ALUMINIUM CANNOT BE DEEP DRAWN ,BUT THE OUTER PANEL; CAN BE DEEP DRAWN BECAUSE OF THE STRUCTURE .

THE PURPOSE OF USING THE ALUMINIUM BACK DOOR IIS IT IS HAVING LESS DENSITY.

SO THE FINAL WEIGHT OF THE PRODUCT IS LESS ,IN THE ALUMINUM WE CAST THE PART AND WE CAN GET A VARYING THICKNESS WHERE WE WANT ,SO WE CAN AVOIDS THE REINFORCEMENT COMPLETELY.

AT THE NED ,THE INNER PANEL ASSEMBLY IS ITSELF ONLY BE ONE PART AND THE WEIGHT WILL BE DRASTICALLY REDUCED.

DESIGN METHODOLOGY OF ALUMINIUM PART IS QUITE DIFFERRENT COMPARED TO THE STEEL.THE NATURE OF ALUMINIUM IS DIFFERENT.

IF WE MAKE THE BACKDOOR WITH THE ALUMINIUM. IT IS NOT NECCESARY THAT WE HAVE TO GIVE THE CLEARENCE OF THE 3mm ,IT CAN BE 2mm.

NEEND NOT TO GIVE THE MINIMUM DRAFT OF 7 DEGREE  .IT CAN BE 5 IT CAN BE 3 DEGREE ,BECAUSE WE HAVE TO MAKE THE PART BY THE DEEP DRAWING PROCESS, IN WHICH WE CAN BE HAVE THE DRAFT ANGLE LESS THAN THE 7 DEGREE . BUT MAKE SURE THAT IT IS HAVING THE POSITIVE DRAFT.

WHICH RESULT IN THE LESSER VOLUME OF THE BACK DOOR . WHICH RESULTS IN THE INCREASE OF THE LUGGAGE AREA.

DIFFERENCE BETWEEN ALUMINIUM AND STEEL.

                            ALUMINIUM                                                                                          STEEL

PARTS ARE CASTED                                                                                           STAMPED

COST MORE                                                                                                     LESS COST

DENSITY LOW                                                                                                  MORE

BUT IF WE MAKE THE BACK DOOR BY THE STEEL .WE HAVE TO DESIGN THE DIFFERENT PARTS .

WE HAVE TO GIVE REINFORCEMENT.

LIKE THE LATCH REINFORCEMENT,

HINGE REINFORCEMENT ,

GAS STAY REINFORCEMENT

WIPER MOUNTING REINFORCEMENT.

WHIH IS SHOWN BELOW. 

HEMMING PROCESS.

IT IS USED TO JOIN THE OUTER PANEL AND THE INNE PANEL .WE HAVE TO ALSO PROVIDE 2 mm CLEARENCE AT THE UPPER AND THE 2mm CLEARENCE IN THE BOTTOM SIDE.BECAUSE THE PASTE WE GIVE TO JOIN BOTH THE PANELS , WILL HOS OUT . SO IT WILLNOT LOOK BAD SO WE PROVIDE THE CLEARENCE .

COMPONENTS OF BACKDOOR .

1.OUTER PANEL UPPER

THESE ARE THE PANEL EXTRACTED FROM THE GIVEN STYLING SURFACE.

THICKNESS OF THE UPPER PANEL IS 0.75mm.

2.OUTER PANEL BOTTOM

TOOLING DIRECTION.

BEFORE WE START THE DESIGN OF THE BACK DOOR.

FIRST WE HAVE TO MAKE THE TOOLING DIRECTION FOR THE DEEP DRAWN PURPOSE .

DEEP DRAWN PURPOSE IS THE USED TO MAKE THE INNER PANEL OF THE BACK DOOR.

DRAFT IS ALSO PROVIDED WITH RESPECT TO THE TOOLING AXIS.

3. INNER PANEL

IN THIS WE USE THE Y EMBOSSES DESIGN. TO PROVIDE THE STRENGTH AND TO DIVERT THE FORCE TOWARDS THE HINGE JOINTS.

AND WE ARE MAKING THE HOLE ,WE HAVE TO MAKE THE HOLE ON BOTH SIDES AND MAKE SIMILIAR HOLES ON BOTH THE SIDES. BECAUSE IF IT IS NOT THE SAME,IT RESULTS IN THE MORE WEIGHT ON ONE SIDE ,WHICH REULTS IN THE CENTRE OF GRAVITY NOT BE IN THE MIDDLE OF THE BAKDOOR.

THE PICTURE SHOWN ABOVE IS THE PORTION WE MADE FOR THE MASTIC .

THIS WILL JOIN WITH THE OUTER PANEL WITH THE HELP OF THE MASTICS.BECAUSE WE CANNOT JOIN IT WITH THE HELP OF THE SPOT WELDING .BECAUSE IT WILL MAKE IT UGLY .RESULTS IN THE BAD ASTHETIC LOOK.

AND IT WILL HELP TO REDUCE THE RATTLING SOUND THAT OCCUR WHILE THE VEHICLE IS IN THE MOTION.

REINFORCEMENTS:

WHAT IS REINFORCEMENT ,THE FIRST QUESTION ARISE , THE MAIN PURPOSE OF REINFORCEMENT IS TO GIVE THE STRENGTH TO THE PART WHICH IS REDUCED BY THE REMOVAL OF THE PART FROM THE PANEL.

IT IS MADE BY THE EXTRACTING OF THE SURFACE NEAR THE HINGE POINTS WE HAVE MADE .

AND GIVE THE THICKNESS OF THE 1.5mm. 

AND GIVE CURVE TO THE SHARP EDGES TO RREDUCE THE STRESS CONCENTRATION.

4.HINGE REINFORCEMENT RIGHT HAND

5.HINGE REINFORCEMENT RIGHT HAND

6.GAS STAY REINFORCEMENT LEFT HAND

7.GAS STAY REINFORCEMENT RIGHT HAND

8.WIPER REINFORCEMENT

9.LATCH REINFORCEMENT

FINAL BACK DOOR

 DRAFT ANALYSIS OF THE BACK DOOR.