Design of backdoor

from the above challenge firstlw we are able to get to know the various type of mounting used for the car back door mounting

Types of back door

• Top Mounted Door
• Side mounted Door
• Bottom Door

Design consideration for the back door

• Rear Visibility Criteria
• Luggage area
• Hinge And Gas stay reinforcement
• Latch and Striker reinforcement
• Draft analysis for tooling axis

The various load cases on the door are :

• Bend Test
• Torsion Test
• Abuse Test
• Dent Test
• Endurance Test

Back Door Assembly parts:

• Inner panel
• outer panel
• hinge and its reinforcement
• wiper motor reinforcement
• latch & stricker and its reinforcement
• gas stay reinforcement

now we start to design the back door assembly with the help of given inputs firstly we sew all part together and try to make a body but some faces are not approprtiate so we create new faces at the require portion and made a body then we had applied the edge blend on the part edges at the require portion. one portion is at the meeting of two surface at that point we made the blend corner and finally we get the final product of class a surface

then we start working for creation of outer panel and inner panel. firstly we made the upper outer panel and lower outer panel seperately

Back door outer lower panel is also made with the same and then we start to create the inner panel firstly we have to create Sealing Flange by offsetting the outer panel to the specific distance.

then we create connecting flange ,wind shild panel,seeling flange and inner panel flange and then we create the emboss for the strengthening the part. The wiper motor mounting with latches and hinges are created on the inner panel. the edge blend are applied on the corners.

The offset of the curve is applied to trim the surface to provide the gap in hemming panel

the thicken operation is perform on the panal after creating the mirror geometry of the part .

we create the hemming flange for outer panel in which we create the offset of the panel and trim it. sweep operation is perform on the outer panel and trim part. sweep operation is repeted from both the edges and at intersection point we made the through courve mesh to joint both sweep. All part are sew toghether to form the single surface. then we provide the edge relif for the sharp corners.we made the mirror again sew both part toughter. finnaly we perform the thicken operation on the part to do the part thicken.Same procedure is followed for the outer lower panel.

The reinforcement are created on the inner panel to strenghen the component at hinges strikers and the wiper motor mounting as shown in bellow

after creating all the reinforcement we have created the thicken part.

Draft Analysis

Draft Analysis is done to analyze the draft angle. This allows us to verify whether the product will be easily removed from the tool.

When designing a product they need to be angled slightly so that the tool can be pulled away from the object easily, without deformation or damage. This slight angle is called draft. for the inner panel is as shown

we also perform the draft analysis for the outer upper and outer lower panel as given bellow

outer panel upper draft analysis

Conclusion

Thus the Back door was designed and developed from the given styling surface with essential reinforcements and emboss definitions. Draft analysis was also done on the Inner Panel,outer panel.