Design of backdoor

REPORT

MY OBJECTIVE IS TO CREATE ASSEMBLY OF BACK DOOR BY USING CLASS A SURFACE (AS A BIW ENGINEER)

• FIRST CREATE BACK DOOR ASSEMBLY FILE AND IN THAT ASSEMBLY FILE CREATE FOLLOWING PARTS AS MODEL FILE

1. OUTER PANEL UPPER
2. OUTER PANEL LOWER
3. INNER PANEL
4. HINGE REINFORCEMENT LEFT SIDE
5. HINGE REINFORCEMENT RIGHT SIDE
6. GAS STAY REINFORCEMENT LEFT SIDE
7. GAS STAY REINFORCEMENT RIGHT SIDE
8. WIPER MOTOR REINFORCEMENT
9. STRIKER REINFORCEMENT

• THEN FIRST STARTED WITH THE GIVEN SURFACE CLASS A AND CREATE WAVE LINK GEOMETRY IN THE INNER PANEL PART
• THEN OFFSET WITH DISTANCE OF 1.7 mm
• THEN CREATE FLANGE FOR SEALING

• CREATE THE INNER PANEL WITH THE EMBOSS AND LAW EXTENSION COMMAND

• THEN CREATE REQUIRED INNER PANEL USING TRIM SHEET
• MIRROR THE HALF SECTION PANEL TO GET THE ENTIRE INNER PANEL AS SHOWN BELOW

• THEN PERFORM DRAFT ANALYSIS ON INNER PANEL
• IF IT SHOWS GREEN THEN IT CLEARED DRAFT TEST

• AS ABOVE THE PORTIONS AT THE EMBOSS CUT BY USING LANSING OPERATION

THEN WE CREATE HEMMING FLANGE

• FOR HEMMING FLANGE WE OFFSET OUTER PANEL 2.65mm
• THEN CREATE 9mm OFFSET LINE FROM THE EDGE AND TRIM THE SHEET
• THEN USING THREE FACE BLEND OPERATION AND CREATE HEMMING FLANGE

• THREE FACE BLEND APPLIED FIRST SELECT TOP FACE THEN BOTTOM FACE AFTER THAT SELECT SIDE FACE
• THEN HIDE THE SIDE FACE (ENSURE TRIM AND EXTEND AND SEW IS SELECTED DURING FACE BLEND)
• THEN PROVIDE CORNER RELIEF

• THEN CHECK FOR DRAFT ANALYSIS

SAME FOR THE OUTER PANEL LOWER

• FOR REINFORCEMENTS FIRST CREATE SURFACE WAVE LINK GEOMETRY UPPER FACE OF INNER PANEL
• THEN TRIM ALL THE EDGES AND PROVIDE CORNER RELIEFS WHER EVER IT IS REQUIRED
• REINFORCEMENTS ARE GENERALLY CREATED FOR STRENGTHEN THE FASTENING AREA
• REINFORCEMENTS ARE GENERALLY DIFFERENT MATERIAL THAN PARENT SURFACE
• USED WHEN SCREW FASTENING IS THERE BETWEEN TWO PARTS, AS A SUPPORT

SAME FOLLOWED FOR ALL THE REINFORCEMENTS

• TOOLING AXIS CREATION

1. HERE TWO LINES ARE CREATED FROM ONE END TO OTHER
2. THEN CREATE A BISECTING LINE OF THAT TWO LINES
3. THEN MAKE THOSE AS REFERENCE LINES

• NOW HOW TO CREATE STRIKER MOUNTING?
• FOR THAT FIRST CHOOSE A POINT OF HINGE ROTATION
• THEN THAT POINT AS CENTER AND DRAW A CIRCLE WHICH PASSES THROUGH THAT POINT SHOWN BELOW
• THEN DRAW A LINE TANGENT TO CIRCLE FROM THAT POINT
• THEN LINE FOR CUTTING MATERIAL IS CONSTRUCTED PERPENDICULAR TO THAT LINE
• THEN MAKE USE OF LAWEXTENSION TRIM EXTEND COMMANDS

• BLEND CORNER USED AT THE THREE EDGE BLANDS MEETING AREA
• BY SELECTING THREE EDGES IN A SEQUENCE MANNER AS SHOWN BELOW

• TRIMMED SOME PART IN INNER PANEL TO AVOID DRAFT FAILURE
• ALTHOUGH THAT REGION MADE BY SEPERATE MANUFACTURING PROCESS
• IT SHOWN IN BELOW PICTURE

I USED CURVE ON FACE COMMAND WIDELY DURING MY DESIGN

• IT IS A VERY HANDY TOOL AND GIVES EXACT RESULTS
• HERE I SHOWN HOW I SELECTED POINTS FOR CURVE ON SURFACE
• AND IT USED FOR PROVIDING CORNER RELIEFS AT REINFORCEMENT DESIGN
• G1 TANGENCY OPTION IS USED AT END POINTS

NEXT ONE I USED MORE FREQUENT IS BRIDGE CURVE

• BRIDGE CURVE IS USED FOR MAKING THE CORNERS SMOOTH
• PROVIDE SOME DISTANCE FROM TIP SO THAT SHARP EDGE GETS VANISH
• HERE SHOWN HOW TO SELECT EDGES

ANOTHER COMMAND IS WAVE GEOMETRY LINKER

• IT IS VERY USED FOR CREATING REINFORCEMENTS
• FOR THAT I TAKE REFERENCE FROM INNER PANEL OUTER SURFACE
• USE FACE AND FACE CHAIN OPTION TO SELECT REQUIRED FACES AND GET THOSE INTO THE CURRENT PART
• IF WE UNCHECK ASSOCIATIVE OPTION THEN INDIVIDUAL SURFACE CREATED
• AFTER THAT PERFORM ALL REQUIRED OPERATION TO MAKE AS DIFFERENT PART

MANUFACTURING METHODS:

• DEEP DRAWING PROCESS IS USED FOR INNER PANEL FIRST LAYER MOULD

1. IN DEEP DRAWING TWO DIES ARE OPERATED WITH HYDRAULIC FORCE
2. BLANK IS PLACED IN BETWEEN TWO DIES
3. THE REQUIRED SHAPE IS ACHIEVIED BY THIS OPERATION

• EMBOSSING OPERATION USED FOR VARIOUS EMBOSSED FACES

1. HERE ALSO SAME LIKE DEEP DRAWING BUT THE IMPRESSION AREA AND DEPTH WERE SMALL
2. EMBOSSING USED FOR NAMES AND SYMBOLS ON SURFACE

• LANCING OPERATION IS USED FOR CUTTING THE FLANGE

1. IN THIS OPERATION SMALL CUT IS MADE AND BEND THE SHEET TO THE REQUIRED SHAPE
2. HERE THE LENGTH OF CUT INSIDE IS MORE THAN TOTAL LENGTH OF SHAPE THAT IS FORMED

• ROLLER MILLS USED FOR MAKING HEMMING PART

1. HERE ROLLERS ARE PASSED OVER THE EDGE OF SHEET TO BEND IT
2. AND REPEATEDLY ROLLERS ARE FLOWING TO AVOID SPRING BACK AND ACHIEVE PLASIC DEFORMATION

THANKS