Design of backdoor
OBJECTIVE:
- To design the back door of a car.
- To design an inner panel for the back door.
- To design the necessary reinforcements like Hinge, Gas-stay, Wiper motor, Latch and Striker on basis of engineering standards.
- The Inner panel is subjected to Draft Analysis for verifying whether it satisfies requirements of Deep Drawing.
INTRODUCTION :
The back door of a car is used to access the boot of a car. The back door consists of two or three panels in which the outer panels and inner panel. The inner panel is used for providing strength to the outer panel. The inner panel has created by providing required embosses to give it more strength. The inner and outer panels are joined by using hemming and Mastic Sealant. The inner panel consists of latch that is used to lock the door. The back door during opening condition is supported by gas stay to maintain its position. The door is connected to the roof by sets of two hinges. The back door can be opened either by manually or powered by motor. In recent days back door is made of aluminum by many car manufactures instead of steel.
DESIGN CONSIDERATION :
* Rear visibility criteria
* To despite the good impact distribution angle outside the car
*To create the mastic flange between the inner panel and outer panel to avoid the NVH
* To create the mounting for HINGE ,LATCH & STRIKER , WIPER MOTOTR , GAS STAY EMBOSSES
*To create the REINFORCEMENT for all embosses
TESTING METHODS OF DOOR :
METHODOLGY :
THESE FOLLOWING PARTS ARE CREATED IN TAILGATE :
- Inner panel
- Upper Outer panel
- Lower Outer panel
- Hinge Reinforcements(LH&RH)
- Gas Stay Reinforcements(LH&RH)
- Latch and Striker Reinforcements
- Wiper motor Reinforcements
REPAIRING CLASS A SURFACE :
In given class a surface there is lot of sharp edges and patches so we need to repair that surface then we proceed with design other components like inner panel and other reinforcement
first extract the class a surface and then work on it here i was using extrapolate the surface and then trim it and using multisection and blend command
HEMMING IN OUTER PANEL :
*HEMMING is the to joint the both outer and inner panel
*To offset the outer panel in 2.65mm and using parallel curve to split the surface in 6 to 8mm
*Then sweep the outer panel with 90degree and using TRI-TANGENT fillet to create the hemming
HEMMING RELIEF :
CREATING INNER PANEL :
*First we offset the outer panel for 1.7mm to lower direction
CREATING A TOOLING AXIS :
*To using sketch to create a tooling axis
CREATING SEALING FLANGE :
*TO offset the inner panel in certain mm what we need i give a 30mm,60mm and 80mm
*And using parallel curve i cut the surface where i want the sealing flange must be length 25mm so i give a 35 mm then we give a fillet the length will componset to 25mm
*The sealing flange we keep maintain the distance 6 to 12 mm in from outer edge of inner panel that we always keep in mind
*Then using sweep command sweep the surface towards the inner panel in both edges
*Then trim with inner panel and give 5mm fillet all sharp edges
CREATING INNER PANEL :
*I exteact the upper surface from inner panel and middle surface and joint and trim with sealing flange
*Then we need to create the embosses to dispate the force it gives the good impact distripution
*mastic flange in used to joint the inner and outer panel using joining operation
HINGE EMBOSS :
*Hinge emboss is important companent in tailagte it is using to join with roof and tailgate this is joint component this is opeining in upper direction so i created the the emboss in top of the tailaget
COMMAND USED:
* SKETCH
* EXTRUDE
* SPLIT
* SWEEP
* TRIM
* EDGE FILLET
GAS STAY EMBOSS:
*Gas stay is supporting component whnenever we open the door to support and keep the door in this nmain working fuction of gas stay
the gas stay mounting in bascially in side of the door the deisgn procedure follwed in gas stay also
WIPER MOTOR EMBOSS :
* Wiper motor is mounted in center of the tailgate are bottom of rear mirrior
LATCH & STRIKER EMBOSS:
Latch and Striker emboss were designed by creating a trajectory that follows the opening and closing of the back door with respect to the axis of the hinge.
SYMMETRY INNER PANEL :
THICKEN THE SURFACE :
* Go to part workbench and thicken the surface 0.75mm in upward diraction and gives the edge fillet wherver the sharp edges
REINFORCEMENT :
*REINFORCEMENT is gives you to strength the emboss and it's dont allow to bend the emboss it's supporting component
*EXTRACT THE EMBOSS AND SPLIT THE WHEVREVER WE WANT AND THICKEN THE SURFACE 1.5MM
*HINGE REINFORCEMENT :
GAS STAY REINFORCEMENT :
WIPER MOTOR REINFORCEMENT :
LATCH & STRIKER REINFORCEMENT :
FINAL OUTPUT :
GEOMENTRICAL TREE :
DRAFT ANALYSIS :
*TO PERFORM DRAFT ANALYSIS to chechk the component was created the proper angle or not in SHEET METAL the minimum draft angle is 7degree
*Drafta angle gives green colour its a positive result
*OUTER PANEL :
*INNER PANEL :
CONCLUSION :
Thus the Body In the White Back Door of a car was designed by following the engineering standards & also the deep drawing requirements consideration.