Challenge

Design of backdoor

AAkash Kumar14 Dec 2022

BACK DOOR: Back door is part of the Body in white (BIW) this door exists back side of the car and provides extra space to carry luggage. this door is made of different parts and different materials which provides it with lightweight, high strength and extra durability. This back door also provides a backside view for the passenger and driver to view the outside area behind the car.

Main Components of back door Design :

Back door Inner panel design
Back door outer Upper panel
Back door outer Lower panel
Hinged Reinforcement
Gas Stay reinforcement
Hinge and Striker Reinforcement
Motor Mount

Various Methodology of manufacturing Sheetmetal for making the Back door Main components

Punching and Blanking: In the punching operation the product produced hole is Useful while in blanking the product produced Blank/Disc is useful.

Deep Drawing Operation: Flat thin sheets are formed into cup-shaped components by pressing the central portion of the sheet into a die opening using a punch to draw the metal into the desired shape.

Emboss: This operation makes raised figures on sheets with their corresponding relief on another side. The process essentially involves drawing and bending the metal.

Hemming: In this operation, 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 in assembly, improve the appearance of a part and reinforce part edges.

Hemming operation is used for closing the back door upper panel and back door Inner panel and another part.

commands used: Sketch, project curve, trim, bridge, extend, offset in the face, sweep, through curve mesh, law of extension, edge or face blend, offset surface, thicken, blend corner, trim sheet, extend sheet, trim and extend, sew, Emboss, Extract geometry, Mirror geometry, Wave geometry linker, Draft analysis.

Designing of Back door with their components from given data :

Given Back Door Skin sheet metal :

1. Back Door Outer Upper Panel :

the upper panel is made from the back door skin data.

The back door's upper panel is a most outer side surface which gives an attractive look behind the car. it is made of 0.75 mm thick sheet metal which has stylish curvature and visibility criteria for looking behind the car passenger and driver. It gives some protection also from external accidental collision.

Hemming has created the upper panel

2. Back Door Outer Lower Panel:

The back door is divided into two panels, the outer lower panel is the same as the upper panel because it is easy to manufacture and assemble them. it is also 0.75 mm thick.

3. Back Door Hinge Reinforcement :

The back door hinge reinforcements provide the strength for the back door's inner panel so that we can fasten or close the hinges which can bear the load and avoid the tearing of the inner panel from the hole which exists for tightening and hinging the back door from the car. hinge reinforcement can work also as a gasket or washer so that hinges can be tight perfectly.

4. Back Door Gas Stay Reinforcement :

Gas stay reinforcement is provided for giving strength to the inner panel and fastening can tight properly so that the gas stay rods can be attached. one end is connected to the car chassis and another end is connected to the back door.

5. Back Door Latch and Striker Reinforcement :

Latch and striker reinforcement is provided for giving extra strength to the Inner panel so that during the closing or opening of the back door the inner panel should be avoided tear, wear, and collapse.

6. Back door motor mount :

the motor mount is used for placing and tightening the whipper motor which will oscillate the whipper rubber for cleaning the back door glass window.

7. Back Door Inner Panel :

The inner panel is the most important part of the back door in which all component of the back door is mounted.

The back door inner panel should be the strong part over all the back door components. So we have given the embossed on the inner panel in a V shape or Y shape so that If any collision on the back door happens then the collision force should be distributed centre to the outside of the inner panel. In this component, we have given some cutouts, lancing and spaces so that the strength of the inner panel strength increases and essential components can be mounted at their places. this inner panel is also 0.75 mm thick.