OBJECTIVE: - Class A Surface Was Received From The Styling Team.

My Objective Is To develop the Class A

Surface Received into Manufacturable Product Design Following The OEM Design Standards Using CATIA V5
Surface Workbench.

SUMMARY: -
The Project Report explain in brief the Design life cycle followed in the automotive industry While Developing
the Back Door of Cars From a Class A Surface Provided. Using, CATIA V5 Surface Workbench.

PROCEDURE
Class A Surface: -
In Automotive Industry There Will Be a Dedicated Team Who Will Perform the Aesthetic Designing of Various
Components Including The Whole Vehicle. They Will Create Various Concept Sketches After Ideation. After
That, They Will also create a Class A Surface Of The Product. This Class A Surface Is Then Passed Over To The
NPD CAD Team. They Will Initially Inspect The Class A Surface In Order To Check If The Design Is
Manufacturable Or If It Is Following The Engineering Principles. If There Are Any Issues About The Design, They
Will Contact The Product Design Team And Will Ask To Modify The Class A Surface In Order To Solve The
Problem. Here I Received The Class A Surface of Back Door.

The Main Parts of the Back Door:

-Inner panel
-Outer panel
-Hinge reinforcement
-Gas stay reinforcement
-Wiper motor reinforcement
-Latch/striker reinforcement
-Hemming
 DESIGN METHODOLOGY

Back door Styling Surface

Tooling Axis

Door Outer Panel

Hemming Definition

Door Inner panel

Sealing Flange Definition

Emboss, Latch Striker

Trajectory

Tooling Axis Draft Analysis

Reinforcement Mountings

-when I inspected the Surface which got from the styling team having lots of irregularities and patches. All the
patches and irregularities are clear by me after discussion with the styling team.
For Tooling Direction:-
-the inner panel 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 core is known as a
tooling direction. The tooling direction/axis is created by me So, that Manufacturing team take the reference
of this tooling Axis and Manufacture the part accordingly.

Outer panel:
-The outer panel of the back door is similar to other BIW components where it is the aesthetic part of a
vehicle. The coating provided is of multi-stage which has the property of scratch resistance, rust prevention
and smooth and attractive finishes. The outer panel also has the provisions for the tail lamp, rear fog lamp and
also has the provision for licence plate mountings. Most of the hatchback cars have the provision for wiper
motor.
-Inner Panel
-Here the inner panel is created for strengthening the door assembly and it is one of the most important
components on which all accessories are mount like hinges, glass guide channel. Back door inner panel is
mounted with the Roof. The weight of Door inner panel is near about 7to8kg depends upon its material and
its thickness. The possible method is the integration method. In the integration method, the part is stamped
out of a single blank. This reduces the number of tools needed; the assembly cost, and eliminates any fit ability
problem.
-To Create the inner panel of the back door. Firstly, Make an offset of 1.7mm. From the outer panel. Here I
considered 1.7mm offset because the inner panel and the outer panel is going to be thicken 0.75mm inwards
side & 0.2mm Gap is needed to be given for the mastic sealant.

-here To Create the Sealing flanges on the inner the panel. I the Extracted the Surface from the outer panel &
then offset by 25mm.
-Here I have taken offset of the curve and then split it with the offset surface. After splitting, the small strips
are connected by drawing the proper curve as the guide for the multi-section surface.

-The tail lamp part is offset to 65mm and untrimmed followed by splitting to have a continuous smooth
aesthetic surface.
-Similarly, I have done For the whole boundary. All the small surfaces are joined to gather form the lower
Sealing flange of the inner panel.
-Later on, edges are Swept along the tooling direction with the draft angle of 15 degrees (all the parts
designed have to be producible).
-Then, the swept surface is trimmed with the parent surface the extract.
-Later on, edges are swept along the tooling direction with the draft angle of 15 degrees (all the parts designed
have to be producible).
-Here The surface of the inner panel is created using the multi-section and then extrapolating
and trimming.

-At the trimming region of the upper and lower panel, the gap is filled using the blend and connect
curve
Mastic:
-Since we are reducing the overall weight of the door, this mastic providing the strength also serves the
purpose of joining the inner and outer panels using the mastic sealants.
The mastic sealants help in reducing the NVH(noise, vibration, and harshness )levels of the door.
Create a Sketch and provide a cut out on the surface. Now, use the sweep option to create the surface
perpendicular to the base surface.
-Offset the main surface to 5mm and trim the surface with the sweep. Cut the unnecessary elements and
make sure the trimmed outer surface is less than half of the length of the cut out created at the bottom.

-Now, the free corner of the mastic is provided with relief by drawing the spline and then
splitting it with the surface. The edges are provided with the appropriate fillets.
EMBOSSING

- Creating emboss in the outer panel direction because when collision happens from backside of the car this
impact initially falls on the embossed faces then force dissipates according to the design of emboss then the
remaining force hits the inner panel. For this case I designed my emboss towards outer panel direction.

-Emboss should be in 7 degrees to 25 degrees inclined in angle and it should not be in 90-degree angle, why
because when we do stamping in manufacturing the stamping tool fits the sheet metal hence it will not come
out of that sheet metal, So this is the main reason why the emboss face is in angle.

Hinge and gas stay:

-Hinge is used to connect the door to the BIW also enables the opening and closing of the hood. So, the
embosses are created of the hinge along with reinforcements to provide additional support to the inner
panel.
-The Hinges are created at the top of the inner panel using the parallel curves and corner option.
-Use the split option to cut the elements and perform a sweep with an angle of 10 degrees. Offset the surface
to 4mm and trim it with the sweep surface. Give the fillets of 4mm to it.
-Similarly, the gas stays embossment is created at the side of the inner panel following the above steps as
mentioned for the hinge.
Latch:

For the latch, it is important to keep the latch embossment according to the trajectory the door opening and
closing follows.
-Take create a centre point between the two hinge parts and draw a circle marking the sweep of the lower end
of the inner panel. Draw a Tangent to the Circle and create the cut on the tangent area and give the cut-outs
to it.
-Now draw the sketch on the plane where the circle intersects the inner panel lower side or where the latch
follows the trajectory properly.
-Sweep the drawn sketch at an angle along the tooling direction.
-Now, split the surface with the inner plane and then fill the opened surface followed by stitching all the
surface.

Wiper :
-Similarly, the embossment for the wiper motor has been created as shown below.

Reinforcements:
-Reinforcements and embosses are added or designed to compensate for loss of strength in a region or area
due to the load acting there. In back door's case load acts in the form of Hinge, Gas Stay and Latch & Striker.
These load cases are determined with the help of various tests and simulations.
-Thickened the inner panel and extract the hinge and around surfaces.

-Now, Split the surface to obtain the required reinforcement surface.

-Thickened the surface to 1-1.2mm since the reinforcement has to be stronger than the panel.

Gas stay Reinforcement:

-Gas Stay is a device used for supporting the back door in its open position. Gas stay requires no man power
and is engaged into support position automatically as the back door opens. One end of the Gas Stay is fixed on
the backdoor and the other end on the Body Side or on the Back door stationary area. Embossing is provided
at the Gas Stay mounting area to compensate for the functional holes punched.
Various simulation tests like Bend test, Torsion test, Abuse test performed on the back door , there a very
weak zone developed at the Gas stay region. To compensate that, a reinforcement is added in that region.

Latch reinforcement:
-The Latch & Striker forms the locking mechanism of the backdoor with the car. Due to regular opening,
closing and over slamming of the backdoor, there is stress developed in the Latch and Striker area. Further,
during a rear collision this area will be the first point of contact. To compensate for the same, reinforcements
are added in this area.
Draft analysis :