Design of backdoor
BACK DOOR(TAILGATE):
Back door is one of the component of the vehicle, which is located at the backside of the vehicle or next to the passenger seatwhich provide the boot space of the car .The back door is opened and closed objective with the help of gas stay mechanisum and it is hinged to the vehicle with the help of hinges.It colud be provide the safety to the passenger from the accidents and also dust, rain, wind etc. there is no possybilities for entering the wter into the car by the back door because the rubber material is attached to around the back door. The back door uses less times when comparing the the vechile side doors.
* TYPES OF BACK DOORS:
1. Top Mounted Back door
2. Side Mounted Back door
3. Split Type Back door
ASSEMBLY PARTS OF THE BACK DOOR:
1. Back door Upper Panel Outer
2. Back door Lower Panel Outer
3 Back door Inner Panel
OTHER COMPONENTS OF BACK DOOR :
1. Hinge reinforcements
2. Gas stay reinforcements
3. Wiper motor reinforcements
4. Latch & striker reinforcement.
MANUFACTURING PROCESSES OF BACK DOOR :
The vechile's back door is BIW component, So the back door is manufactured by metal forming process. There are different types of metal forming processes used to manufacturing the door panels there are deep drawing, stamping, casting, moulding, extruding etc. From these, stamping methodology is used to produce the back door panels.
STAMPING PROCESS:
Stamping is a cold forming processe that makes use of dies and stamping presses to transform sheet metal into different shapes. The flat sheet metal typically refferd to as blanks, is fed into sheet metal stamping press that uses a tool and die surface to form the matal into a new shap.
DESIGN CONSIDERATION OF BACK DOOR :
We should follow these considerations before starting the backdoor design.
1. Rear visibilty criteria
2. Reinforcements
3. Boot space
4. Embosses
5. Rear crash regulisation
DESIGN OF BACK DOOR:
As input of the back door styling part which is provided from the styling team, we should check that wether it is perfect part or not for the designing. After checking the styling part ,I realise that the part is irregular and somwhere there is no tangent continuty . So i should reapir that styling part as required before the designing.Finally we hove to design the back door by using these repaired styling part as referance. In back door assembly there are parts like upper panel outer, lower panel outer and inner panel whicH is needed to design from the referances.
1. BACK DOOR UPPER PANNEL OUTER :
The back door upper panel is a BIW component, manufactured by the process of stamping.It covers the outer side of the back door and it have some sufficient strength and it is also styling part of the back door. The back door upper panel outer has some cutouts as required shape for the rear tail lamps. It is joined with the lower panel outer of the back door.
2. BACK DOOR LOWE PANEL OUTER :
The back door lower panel also a BIW component, manufactured by the process of stamping. It is located at the bottom side of the upper panel, It is joined with the upper panel by the process of spot welding. Hemming operation is also carried at the edges of the both panels which is joined with the inner panel of the back door. Mostely the number plate of the vehicle is placed on this back door lower panel outer.
3. BACK DOOR INNER PANEL :
In back door the inner panel plays major role, It is located at inner side of the upper panel outer.Mountings and all the other components of the back door like hinge reinforcements, gas stay reinforcements, wiper motor reinforcements and latch and striker reinforcements are arranged on this panel, and also it has some embosses for increasing the strength of the inner panel and distribute the power while the rear crash. So the back door of inner panel should be stronger.It is similarly manufactured by the process of stamping.
REINFORCEMENTS OF BACK DOOR :
The purpouse of the reinforcements is provided the additional local strength at the required places which are hase some low strength. In an inner panel there is types of mounts are provided for the different uses. On these mounts some moving objects are mounted like hinges and gas stay etc. So there some stress will be created by these objects. Therefour we need to provide the additional strengths like reinforcements.
1.HINGE REINFORCEMENTS:
2.GAS STAY REINFORCEMENTS:
3.WIPER MOTOR REINFORCEMENTS:
4.LATCH & STRIKER REINFORCEMENTS:
HEMMING OPERATION :
The hemming process should be used where the parts are styling parts and also spotwelding and reveting does not required. In hemming operation there should be some stress relevings are provided at the corners.
DRAFT ANALYSIS :
We should provide the the minimum draft angle of 7 degrees because it is easyer for the manufacturing the back door.
FINAL DESIGN IMAGES OF BACKDOOR:
Thickness of the all panels =0.75 mm
thickness of the all reinforcements= 1.15
CONCLUSION
The back door design is completed by using of nx software by following the design considerarions and the draft angle was checked wether the part is menufactured or noy.