Design of backdoor

here we are creating the back door design from the given class-a back door surface

now, we will discuss about the backdoor, and it working.

Back door in the cars mainly used to cover the back portion of the car and act as the door foor the boot space, in some other cars it act as only door for IN COMING and OUTGOING,

types of the back door based on the opening and mounting

1 . roof mounting back door

2. side mounting door

3. bottom sill mounting door

Design criteria of backdoor

1. rear visuality
2. prevention of water incoming from back
3. passing the crassh test
4. reniforcements for strength the backdoor
5. locating wiper mounting & stricker

main parts in the back door

1. outer panel upper
2. outer panel lower
3. inner pannel
4. reniforcements

manufacturing of backdoor

• manufacturing is done in two ways
• stamping and casting
• stamping is done for steel back door
• casting is done for the aluminum backdoor
• when we using the stamping process we requird the reinforcements, because in stamping the back door is formed in uniform thickness.
• to stregth the back to in critical areas we need the reinforcements.
• when we are using the casting process no need of reinforcements, because in casting we can form at varible thickness.
• casting only used for the aluminum beacuse, we add more thickness in the casting to eliminate the reniforcements.
• if the thickness is increase then the weight of of the backdoor will decrease thr performance of tthe car.
• but many companies with go with the stamping process using the steel because the cost of the aluminum is more higher than the steel
• in high end companies like BMW,AUDI,VALVO etc are started usng aluminium back door in there cars.

Design of Backdoor

by using the class-a surface the we will start the back door design

the main part in the back door design is the inner panel, we will start with inner panel.

Inner Panel :

Inner panel is the one of the most important part in back door, where all the reinforcements are mounted onth einner pannel only.

inner panel is the most strengthen part in the back door.

all the wiring harness , reinforcements, wiper mountings, stricker mounting and back camera all are placed on the inner panel.

when the crash happends the using the embosess on the inner panel the force is diverted to outside, effect to the passengers inside the car will reduce.

outer pannel:

in outer panel there will be two parts

1. outer panel upper

2. outer panel lower

the outer panel upper will take the windshiled area and the gas stakes and wiper mounting

the outer panel lower area will take the lower lights and rear sensors and camera and stricker

in the outer panel the hemming opertion is the critical areawhich holds the inner pannel

hinge mounting reniforcement

hinge mounting will be conneted to thr roof which helps to open the door and close,

these areas needs more strength so we will add reniforcements to that area.

gas stake mounting reniforcement

gas stake will be conneted to the back door and flange which helps to open the door and close,

these areas needs more strength so we will add reniforcements to that area.

wiper mounting reniforcement

wiper will be conneted to the back door which helps to clean the back windshield,

these areashave wiper motor which needs more strength so we will add reniforcements to that area.

stricker mounting reniforcement

stricker will be conneted to the back door which helps to lock the back door,

these areas have lock which needs more strength so we will add reniforcements to that area.

placement of latche & stricker with trajectory:

the back door will rotate arount the hinge axis, by using that we will create thee latche & stricker trajectory, which will helps for the correct opening and cosling of the the back door.

1st we will create the hinge axis and draw one circle using the axis, then we will draw one tangent to circle and intersection for the tangent line and circle one line will be drawn to cnter of the circle

at circle is called trajectory of the latche and stricker.

Draft analysis

Draft analysis is the one of the main and important in the sheet metal parts using from press tool required the postive draft angle are parallel to the tooling direction.

the same tooling direction will be given to the manufacturing unit which help them in manufacturing time. if there is any -ve angle in the part the part will struck in the die or press and damge will happend to the part and die also.