Design of backdoor

Aim: 

• To Design the BackDoor with the provided styling surface ,using appropriate design methodologies, and providing the necessary reinforcements and embosses.

BackDoor:

• It is a hinged board or door at the rear of the vehicle that can be moved up or down during loading and unloading.
• Back doors are one of the type doors of the vehicle which are located next to the passenger seat which provides access to the luggage compartment. 
• In most of the cars, these back doors are operated with the help of gas stay which in turn reduces the effort required to lift open the door.
• Some luxury cars have powered backdoor which in turn is driven by an electric motor.

                                                                                                      

Gas Stay Type BackDoor:

• Gas Stay backdoor are most commonly used in both luxury and lower range model cars.
• Ideal components of the Tailgate are Hinge, GasStay, sealing flange.

                                                                                                 

Electrically Powered BackDoor:

• Powered trunk Lift system consists of a power latch, anti pinch switch, PTG assly, PTG main switch. When the switch is pressed in the compartment or outside the power latch releases the latch and the entire backdoor is opened

                                                                 

 BackDoor Assembly:

1. Inner Panel
2. Outer Panel
3. Hinge Reinforcement 
4. Gas stay Reinforcement 
5. Latch striker Reinforcement 
6. Wiper Motor Reinforcement

1.Inner Panel:

• Inner Panel of backdoor provides the strength and one of the important components of backdoor.
• Inner panel consist of mounting of Hinge, Gas Stay, Wiper motor , and latch and striker and its Reinforcment.
• It helps in dissipation of force outside with the help of Emboss which provides strength to the panel.

                                          

Tooling Direction-

The back door is going to be manufactured by deep drawing process. In Deep Drawing process have a tool which is core and Die. The core part follows the single Straight path the inclination angle of the core is known as a tooling direction.

                                     

Hinge Emboss and Gas Stay Emboss:

                                      

Latch Emboss:

•  Latch and striker trajectory

                                    

• For Latch Position a circle was drawn from the axis of hinges to find out the trajectory

                                   

Wiper Motor Emboss:

                                       

Reinforcement:

• Reinforcements are generally placed to increase the strength of the panel in localized areas .
• The reinforcements are usually 1-1.5mm thick as opposed to 0.75mm thick panel used in this part.

Hinge Reinforcement:

                                             

 

Gas Stay Reinforcement:

                                         

                                           

                            

Wiper Motor reinforcement:

                                       

Latch and Striker reinforcement:

                                      

Mastic Sealants:

• A mastic sealent is used on the surface to connect the inner and outer panel with a gap of 5mm .                              

Sealing Flange:

• It restricts external matters such as water ,dust  etc 

                                    

Outer Panel:

                                    

Hemming:

• Hemming is a forming operation in which the edges of the sheet are folded over another part in order to achieve a tight fit. 
• Baasically hemming is used to join the outer and iner panel because it doesn't affect the outer panel styling look.

                                  

                                  

Draft Analysis: 

                                             

Final Assembly: