Side door design
BODY SIDE DOOR ASSEMPLY
AIM:
The provided styling surface to design the side door, use appropriate design methodologies, and provide the necessary reinforcements and embosses. Need to consider the basic design aspects to design this part according to the Class A design given.
TWO TYPES OF DOORS:
1. FRONT DOOR
2. REAR DOOR
A very critical par, the car side door is typically hinged, sometimes attached by other mechanism such as track. They can be opened manually or powered electronically.
Unlike other types of door, the exterior side of the vehicle door contrasts sharply from its interior side (the interior side is know as the car door panel)
The exterior side of the door is designed of steel like the rest of the vehicle's exterior.
SIDE DOOR ASSEMPLY ARCHITECTURE:
Side door basically each door has four parts, Inner panel & Outer panel
INNER PANEL:
- Upper inner panel
- Lower inner panel
OUTER PANEL:
- Upper outer panel
- Lower outer panel
There are three industry standard side door architectures
<!-- [if !supportLists]-->1. <!--[endif]-->Header Reinforcement: Header Reinforcement - without a sash(Window frame) on the outer panel but provided with a header reinforcement to support the inner panel. The inner panel upper and lower an integrated together, why the inner panel has one piece and the outer upper and outer lower has separate entities.
- Separate Header: Separate header - Sash less inner and outer panel with a separate header. The outer upper and inner upper has integrated together and outer lower and inner lower separate entities.
- Integrate Header: Integrated header - sashed inner and outer panels. The inner panel and outer panel are separate two entities.
Which is one of the best of architecture the third type is most way of side door followed in average of Indian four door cars.
INNER PANEL: The side door inner panel covers the inside parts of a door mounding pad, for example, the windoe regulator, power window motor, Coin holder, Cup holder, and wiring everythings is integrated in to one module. It function as an interface between the inside of the car and the inner working of the doors the occupants and door in the car.
OUTER PANEL: The side door outer panel cover the inside of the inner panel, belt line, cross beam. All car doors consist of a frame to which trim and window components are mounted, and an outer metal layer that's attached to the outside of the frame. A door skin is the outer metal layer only. A door shell includes both the outer skin and the door frame, and is shipped preassembled with the skin already welded and bonded to the door frame.
HINGES: These hinges are enable the opening and closing of the side door. One end of hing is fixed on the body side outer and other end is placed on the side door inner panel. The hinge reinforcements are added to compensate for the weak region due to the acting load over it.
1. Top hinge
2. Bottom hinge
Hinge Area:
DOOR BELT LINE: This one is nearly reinforcement here its called the door beltline. This is provided to aditional strength of side door impact analysis. This belt line here is mandrative component of every side door.
SIDE DOOR BEAM: One of the functions of side door impact beam is to absorb as much kinetic energy as possible during side impact collision to prevent serious injuries and fatalities to the occupants in the vehicle.
It also provides additional load path between the hinge face and latch face.
The design challenge of the side door impact beam is to have high peak crash load (peak force) and energy absorption capabilities.
Hinge Axis and Striker Position: The principle of hinge axis is to determine the rotary motion of the closing and opening of the side doors. Depending upon that we decide the position of the latch and striker placement (which is always considered as a single entity for practicality).
Ideally for proper load distribution and easier opening and closing of doors, the hinges should have sufficient distance between them.
The Design Considerations:
1. Rusting Occurrence are: The water entering the A-Piller top to direct the hinge area, the hinge are ED coating galvanising process for that metal parts constant contact with the water.
2. Freezing point: The side door has particular curvature and fender is also the same curvature. This curvature help to the easly door open and close, when we open the door they space bedween the side door and the body side begainers the snow fall down.
3. Hinge center: The position of the hinges, we have to place the hinges for towards end of the door (top and bottom of the door) they also keep maintaning the particular distance from the edge. Then we have to leave the curvature and the take about 5 to 10 mm clearance and then place the hinges.
4. Side door open condition of top view: Length have to be long in some type of car so close the door by using the largest amount of force in closing door completely, so we have to use something called as check links, these check links are integrated with hinges and this will enable the door to move the segments.so when we close the door one feel free motion and open condition is we used very minimum force.
DRAFT ANALYSIS: We are apply the minimum draft angle 7degree of below the components.
1. INNER PANEL:
2. BELT LINE:
3. SIDE BEAM:
MANUFACTURING PROCESS:
The stamping process is a metal forming process in which sheet metal is given a desired shape. The stamping process may include different other sheet metal operation like punching, bending,nlanking,shearing,ect.
EMBOSSING: Here is hoe embossing is done on a professional level.
1. Two dies of the intended design are created.
2. The dies are inserted into a heated press.
3. The meterial that's getting embossed is stamped in between the dies.
4. The design is officially embossed onto the material.
HEMMING: Hemming is a sheet metal forming process in which sheet are joined by bending it to 180 degree. The hemming is a manufacturing strategy during which the edge of the sheet of metal is folded over itself meets the surface of the sheet.
CONCLUSION:
The design of the BIW Body side door for an SUV was completed with the engineering standard and all the reinforcement.
Link in side door assemply:
https://drive.google.com/file/d/1_iSkkThlheHAFruTElTPz76D_SGLJ7zK/view?usp=sharing