Design of backdoor

AIM - Design the back Door of the car using given styling surface with the help of NX CAD Software, also provide the necessary reinforcements and embosses.

INTRODUCTION

A door which is located at rear side of the car which give access to the luggage, spare wheel etc. Back Door is a hinged door/tailgate at the rear of the vehicle. This door can be operated manually or electri power. Most of luxury cars the door operated electrically.Some diffrent back door are shown below

TOP MOUNTED

SIDE MOUNTED

Components to design are mentioned below,

• Outer Upper Panel.
• Outer Lower Panel.
• Inner Panel.
• Gas Stay Reinforcement LH And RH.
• Hinge Reinforcement LH and RH.
• Striker Reinforcement.
• Wiper Reinforcement.

All the cmponents are thickened to 0.75mm.

Steps

Checking the Surface

• Open the given styling surface in NX CAD and check the surface and also sew the given surface.

Creation of Tooling Axis.

• Draw a line from left and right extremities almost parallel to the path of the surface along the unsymmetrical axis.
• Using the Derived lines tool, create a bsecting line as shown below,

Creating INNER PANEL

• First offset the surface to a distance of 1.7mm, which will give the innerpanel surface position. Now the sealing flange for the inner panel has to be created.
• The seaing flange created by cuttng from the surface is shown below:

• Now connect the flange with the surface using law extension w.r.t the tooling axis and proper draft given.

• Fillets has to be applied at each steps and check whether the surface is getting thickened or not.

• Similarly connect the lower side of the surface by creating a surface and sew it all together.

• Mastic sealent is used on the surface to connect the inner and outer panel with a gap of 5mm. And also adding some embosses to strengthen the innerpanel.

• The designed inner panel is shown below ,

Creating embosses for Hinge,Gas Stay ,Latch & Striker and Wiper motor

• Now, embosses has to be created for the Hinge, Gas stay, Latch & striker as well as the wiper motor areas.

Hinge Emboss

Gas Stay Emboss

Latch & Striker Emboss

For striker first we find the position using the circle and tanget method ,

Wiper motor Emboss

CREATING REINFORCEMENTS

• HINGE REINFORCEMENT

Using the wave geometry extract the surface of the inner panel and created the reinforcement.After creating one of the hinge reinforcement mirror it to get the other.

GAS STAY REINFORCEMENTS

Using the wave geometry extract the surface of the inner panel and created the reinforcement. After creating one of the Gas Stay reinforcement mirror it to get the other.

WIPER MOTOR REINFORCEMENT

Using the wave geometry extract the surface of the inner panel and created the reinforcement.

LATCH & STRIKER REINFORCEMENT

Using the wave geometry extract the surface of the inner panel and created the reinforcement.

OUTER PANEL CREATION-UPPER

Mirror the surface and thicken the outer panel to 0.75mm

OUTER PANEL CREATION-LOWER

Mirror the surface and thicken the outer panel to 0.75mm

Final ASSEMbly

DRAFT ANALYSIS of INNER PANEL

Using the draft analysis tool, check the surface is clearing or not for given draft angle.

Here the given drat angle is clearing all the sides of the panel.

CONCLUSION

The back door outer and inner panel were designed with the help of the styling surface along the tooling direction.Also the Draft analysis was performed on the inner panel and all the reinforcements were designed and placed at appropriate positions.