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  1. Home/
  2. Satya Mohan Kurumalla/
  3. Design of backdoor

Design of backdoor

DESIGN OF CAR BACK DOOR Objective:  From the given styling surface, develop a back door using appropriate design methodologies. The Design of Back Door of a car consists with an Inner Panel, Outer Panel(Upper & Lower) and Reinforcements for the Hinges, Gas stay, Wiper Motor, and Latch by following the engineering…

  • DESIGN
  • Satya Mohan Kurumalla

    updated on 30 Sep 2022

DESIGN OF CAR BACK DOOR

Objective:

 From the given styling surface, develop a back door using appropriate design methodologies.

  • The Design of Back Door of a car consists with an Inner Panel, Outer Panel(Upper & Lower) and Reinforcements for the Hinges, Gas stay, Wiper Motor, and Latch by following the engineering standards.
  • The Inner Panel must be subjected to Draft Analysis for verifying whether it satisfies the Deep Drawing requirements for the tooling direction created in the design.

 Introduction:

          The Back Door/Tail gate of a car is the rearmost part of the vehicle which gives access to the trunk space/luggage compartment of the vehicle. 

          It provides the aesthetic outer appearance to the vehicle as well as wind flow aerodynamic surface. Tailgate is a single stamped or split outer panel. It integrates with the inner reinforcement panel. To avoid air rushing noise as well metal rubbing noise, protected with the sealer application process. Outer edges hemmed by Robot hemming process with 3 pass hemming to ensure sealer fill rate uniformly as well clinch tightness rigidly. in such a way easy to open at the same time, it should not pass external environmental noise inside the passenger compartment and should not lead to any water leak. High closing effort leads to improper locking. Gas Stay is used to easily access opening and closing.

        The rear door also supports the reinforcements and added weights of the Wiper Motor, Gas Stay, Tail Lamp, and Latch and Striker. It is one of the closure commodities in BIW sheet metal design. The backdoor has a lot of components inside and is designed to incorporate them easily. It affects the rear visibility and luggage area.

       The material used for door manufacturing depends on the budget and performance of the vehicle. Mostly Aluminium and Steel will be used whereas low-budget vehicles use Steel which makes the manufacturing process easy and cost-efficient since it follows the Stamping Sheet of metal.

        

 

 

The Main Parts of the Back Door:

  1. Outer Upper Panel.
  2. Outer Lower Panel.
  3. Inner Panel.
  4. Gas Stay Reinforcement LH and RH
  5. Hinge Reinforcement LH and RH.
  6. Latch & Striker Reinforcement.
  7. Wiper Reinforcement.

 

Tailgate:

             Tailgate is a door at the back of a truck or car, that is hinged at the bottom so that it opens downwards.

Design Intent:

           The intent of the project is to design a Body-in-White (BIW) Back Door of the vehicle considering the engineering standards and manufacturing requirements which satisfies the Deep Drawing Process.

 STYLING SURFACE: 

 

 

Back Door Outer Panels Upper & Lower

The Outer Panel is the styling surface of the back door. Other components of the backdoor are designed with reference to the outer panel. It acts as the outer cover and deals with the aesthetics of the car.

In this design outer panel is divided into two parts: 

Outer Upper Panel:

          The Outer Upper Panel Extracted from a styling surface.

          The panel is altered for the required design with the surface tools of NX CAD

          The thickness provided for the outer panel is 0.75 mm

          Hemming is provided with the corner relief.

Outer Lower Panel

The Outer Lower panel is developed from styling surface, the thickness provided for the outer panel is: 0.75 mm. Hemming is provided with corner relief.

Back Door Inner Panel: 

While designing the inner panel the consideration for its design are Thickness, the gap between the outer panel, and embossing.

The nominal thickness of the inner panel is 0.75 mm

The clearance gap between the inner and outer panel is 0.2mm

Embosses of the inner should follow the force dissipation criteria.

 

Hinge Reinforcement Emboss

Gas stay Reinforcement Emboss

Latch & Striker Reinforcement Emboss

 

 

 

Tooling Direction:

  • Before starting to design the inner panel of the back door the tooling direction for Deep Drawing purpose should be created.

  • Then the styling surface needs to be checked and analyzed since it might have irregularities, hence it must be fixed first.

  • Then the back door was designed using the top-down approach.

 

 

 

 

Hinge Reinforcement Gast Stay Reinforcement

Wiper Motor Reinforcement

Latch & Striker Reinforcement

 

 

Design Considerations of Backdoor:

  • Functional Requirements of Hinge and gas stay

    Striker Position:

    The position of the hinge should be perpendicular to the latch when the latch and striker meets. For that, a circle is drawn from the centre of hinge axis to find the path of the striker. and positioned it perpendicular to the path

  • Rear visibility criteria: Federal motor vehicle safety standard (FMVSS) No. 111, “Rear Visibility,” currently requires that vehicles be equipped with rear-view mirrors to provide drivers with a view of objects that are to their side or to their side and rear.

  • Luggage volume

  • Crash Analysis
  • Bend Test, Dent Test, Torsion Test & Endurance Test
  • Rear Crash Regulation
  • Gap and flushness Requirements
  • Requirement of sealing and its function: In order to prevent water from entering the cabin we are introducing a sealing area where the sealing flange is provided on the inner panel and rubber mounting area is provided on the body side.
  • Joining techniques: 
  • laser brazing welding: Joining methods, in which the brazing solder is melted with the help of an industrial laser, have been used mainly in the mass production of vehicle bodies. There, laser beam brazing is mostly used for joining galvanized metal sheets or lightweight components made of aluminium, but also for other brazing material. Laser automobile brazing is usually realized with a brazing optic that is integrated in a robot. The laser beam is guided along the joint where it melts the brazing solder

              Advantages of Fiber Laser Brazing | IPG Laser Systems

  • Hemming: Hemming is a forming operation in which the edges of the sheet are folded or folded over another part in order to achieve a tight fit. Normally hemming operations are used to connect parts together, to improve the appearance of a part, and to reinforce part edges. 



                                          

The Outer Panels (Upper & Lower) are joined with Inner panel using Mastic sealant, 0.2mm gap given between Inner panel & outer panels for sealant

 

  • Gap and flushness requirement: Mastic Seals: Mastic Seals placed between Inner and outer panel to reduce noise, vibration, and harshness. Every Mastic will have an effect of 80mm Dia.  The inner and outer panel gap is 4 to 5mm. 0.2mm gap is required for the Hemming and that gap will be filled by sealed past.
  • Adding reinforcements and stiffener pad: reinforcements are added where and all the weight is added. On the inner panel, we have Hinges and striker, which are attached to the inner panel so due to this attachment the strength of the inner panel is going weak. In order to strengthen the inner panel reinforcements will play a very important role. A stiffener pad is a sponge-like material place b/w Inner and outer panel to reduce vibrations.
  • Emboss definition: Embosses are provided in the inner panel of the back door assembly. This helps in the weight reduction of the backdoor panels and also dissipates the force during the collision.

 

 

 

 

Draft Analysis:

Draft Analysis is for checking the stamping feasibility in the tooling direction. 

It is a method of checking the draft angle on various faces of a part with a particular direction.

It should be more than 7 deg for aluminum for hard metals, min draft angle is 10 deg.

The draft analysis for the inner panel is shown below.

 

 

Conclusion:

Understood Car Back door design concepts & standards and Created Back door design with Outer panels, Inner panel and reinforcements using styling surface.

 

 

 

 

 

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