Design of backdoor

What is Back Door

  Back Door is called Rear door,Tailgate,Trunk.

  Backdoor are one of the type of door of the vehicle which are located backsisde of the vechicle which provides access to the luggage compartment.

     In the most of the cars, these back door are operated with the help of gas stay which in turn reduces the effort required to lift the door.

Purpose of Back Door

 Provide access to the luggage compartments.

Components in Back Door

 1.Outer Pannel (Lower and upper)

2. Inner Pannel

3.Hinge Reinforcements

4.Gas stay Reinforcements 

5.Latch and Sticker Reinforcements 

6.Wiper Motor Reinforcements 

Design Considerations  

• Rear visibility criteria
• Luggage volume
• Crash Analysis
• Bend Test
• Dent Test
• Torsion Test
• Endurance Test
• Abuse Case
• Assembly Load Case

Joining Methods 

 Hemming 

     Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming is the process in which the edge is rolled flush to itself.

Spot Welding 

    Spot welding used to join inner pannel with all type of Reinforcements.

Mastic Selants

     Aesthetic look purpose we use to join outer pannel and inner pannel.

Material

    Door manufacturing depends on the budget and performance of the vehicle.

Mostly Aluminium and Steel will be used.

Manufucring Methods

Stamping

 Steel which makes the manufacturing process easy and cost efficient since it follows the Stamping of Moulds.

Die Casting

  Aluminium were used for high budget cars.

  Aluminium parts will be mostly die casted hence it has variable thickness which reduces the requirement of reinforcements but improves the performance of the car

Design Procedure 

• Surface error fixing the given upper and lower outer panel skin surface.
•  Main design work is creating inner pannel design
• Initially start to Sealing Flange creation for inner panel.
• Create effective emboss for Hinge, Latch and striker assembly locking areas
• Afterwards create emboss for gas stay and Wiper motor Reinforcements assembly areas and V shape emboss design for strengthen the inner pannel 
• Create Hinge, latch and stricker, Wiper motor and gas stay Reinforcements for avoid tear of the inner pannel from assembly areas of sub assembly parts.
• Inner and outer pannel Joining purpose create Hemming Flange in upper and lower outer pannel outer areas.
• Mostly used tools in NX Cad are Wave geometry liker, offset surface, offset curve on surface, trim sheet, trim and extend sheet, through curve on mesh, thicken, bridge curve, face blends, projected curve and emboss.

Design Assembly Parts

 

Outer Pannel Upper

 

Outer Pannel Lower

 

Inner Pannel

 

Hinge Reinforcements 

 

Gas stay Reinforcements 

 

Wiper Motor Reinforcements 

 

Latch and Sticker Reinforcements 

 

Draft Analysis 

Inner Pannel