Car door manufacturing in Real Industries

Manufacturing Processes -1
Term Assignment (19BME065-73)

Topic
Car Door Manufacturing
Process Analysis
5/24/2021 1:57 AM Car Door Manufacturing Process Analysis 2

The Steps to make a car door
Selection of materials for
car door.
Determining the processes
of manufacturing
Steps to manufacture
a car door

Overview of Material
Used in Cars • Studies by different researches show that the efficient design and increase use
of composite materials into the automotive parts directly influences the car
safety, weight reduction, and gas emission because the efficient design can
absorb more deformation and composite materials have high specific
strength(strength to density) and high specific stiffness(stiffness/density).
• High impact load absorbing and damping properties.
• Side Impact Door should have the ability – absorb as much deformational
energy as possible without breaking.
• Normally Steel is used but Steel increases significant weight of the car.
• Lighter Applications- Composites – Correct Fiber Orientation and Stacking
Sequence of the cross ply laminate contribute to higher energy absorption
when compared to its steel equivalent
• Fuel efficiency of vehicle directly depends on the weight of the vehicle:
The Composite Materials have high specific energy absorption when compared
to steel. The properties like high specific strength and high specific
stiffness are attractive for the construction o f lightweight and fuel efficient
vehicle structures. The energy absorption capability of composite materials
offers a unique combination of reduced weight and improves crashworthiness of
vehicle structures .

Aim of the Project :
• Analyze car door - presently used material – steel
• Replacing - composite materials - Aluminum, Carbon Epoxy, S-glass
epoxy, E-Glass epoxy.
• Impact analysis - conducted on doors for different speeds by varying
the materials.
• Reduce the weight of the door by using composite materials replacing
it with steel.
• Reduces damage percentage of Car and Passenger Protection.
• Pro/Engineer and COSMOS(Solidworks).

Introduction to Car Door
• A vehicle Door – typically hinged but sometimes
attached by other Mechanisms such as tracks in front
of operating which is used for entering and exiting a
vehicle. Opened Manually or powered electronically
• Exterior side of door contrasts sharply from its interior
side (door panel). Exterior side of the door is designed
of steel like rest of the Vehicle’s exterior. (for aesthetic
Appeal)
• Door’s interior made of –vinyl and leather(matched
with interior of car’s dashboard, carpet, seats etc..). A
car door panel has interior parts that contribute to the
overall functionality and ergonomics of the ride –
armrests , lights, electronic systems.

Selection of Car Door Material
Material
Selection
Inner
Material
Outer
Material
Can Provide
Structural Rigidity to
User.
Can Absorb Sudden
External Impacts.

Importance of Selection of Material
Thus, we need to
choose such material
which can meet this
requirement.
Requirements
Should be
designed to
withstand
loads into the
body of the
car while
being thin (<2
mm).
Requirements
Loads could
be horizontal
and vertical in
nature. Requirements
Ability to
protect
occupants
from injury
during a side
collision.

Outer Car Door Material analysis(SAM2X5-630)
To resist the
impact the
material should be
highly elastic.
Tough enough to
get energy on it
absorbed and not
break into pieces
This alloy bounces
back when
deformed due to
sudden impact due
to its high limit of
elasticity.
This material
completely regains
its original shape
because of its
mechanical
properties.
Stuff like Bullet proof
jackets, mobile case, satellite
which has tendency to resist the
sudden impact, this material is
used.
An Amorphous steel alloy.

The composition of
SAM2X5-630
In the ongoing race to
find new material to
perform better under
impact loading,
SAM2X5-630 proves
to be a new
benchmark.
Application of such a
highly elastic material
can be found in other
studies like
1)Impact of meteorite
on satellite shields.
2)Impact of mobile
body falling on floor.
Thus impact borne
application can be
highly benefited by
inheriting the
properties of SAM2X5-
630.
Property Value
Density (g/cm3) 7.75
Young’s Modulus (MPa) 248000
Poisson’s ratio 0.23
Melting Temperature (K) 1133

Conclusion
• After very lengthy analysis of Design
optimization and Multidisciplinary
factors requirement analysis etc.
• It is concluded that the outer door
material analyzed in the present work
should be fabricated using Steel Alloy
SAM2X5-630.

Inner Car
Door
Material
Analyis
Material lightweight engineering which is based
on the use of materials with a high specific
stiffness and/or high specific strength such as
polymer-matrix composites or a synergistic use
of metallic and polymeric materials in a hybrid
architecture
A car door is expected to have properties
like Structure performance, Noice Vibration
Harshness, Crashworthiness, Durability and
manufacturability to it.

Structure performance Requirements
The conditions which the door
must meet with respect to its
frame rigidity and sag resistance.
The Computational Fluid
Dynamics analysis in which the
outer shell of the entire body of
the Ford Taurus was moving in
the forward direction at a speed
of 100 km/h is shown in figure.

Noice Vibration Harshness(NVH) Requirement
The noise, vibration and harshness
requirements for the car door were defined by
determining the lowest natural vibrational
frequency for the door in the close position.
The lowest natural frequency for the closed
door was found to be 30.7Hz and the
corresponding modal shape is displayed in
Figure 4.
The lowest natural frequency for the
composite car door is then required to be at
least 30.7Hz as shown below.

Crashworthiness
The crash worthiness functional requirement for the car door
pertains to the door’s ability to protect the driver/passenger in the
case of a side impact collision.
Typically these requirements are defined as a maximum inward
intrusion allowed under different side-collision scenarios
In this analysis, the bumper of the same vehicle (with an addition
mass of 1,500kg attached to it) is driven into the car door at an
incident angle of 30 degrees and at an initial velocity of 25km/h.
The maximum inward intrusion at the interior panel of the car door
was found to be 223.5mm and this (maximum intrusion) value is
defined as the crashworthiness functional requirement for the
composite-laminate car door.

Durability Requirement
It is generally observed that durability of the inner door panel will be assumed to be
controlled by fatigue–induced failure of its spot welds to the connecting door components
and not by the failure of the panel itself.
Resistance spot welding is nowadays the predominant joining technique in the automotive
industry.
To create a spot weld, two or more sheet-metal components are pressed between two
electrodes and an electric current is passed through. This will fuse both surfaces and we
obtain weld without using any filler material.

Manufacturability Requirement
• The replacement of the initial metal inner panel with a composite-laminate
alternative is considered, the original all-metal door design can not be used
to define the manufacturability requirements for the new design.
• Instead, it is recognized that the composite inner panel will be made by a
Resin Transfer Molding (RTM) process and that it will be made of an epoxy-
matrix composite material reinforced with 50-60% carbon-fiber
plies/laminas.
• Furthermore, it is recognized that the local composite-laminate thickness
and architecture affect the permeability of the carbon-fiber preform with
respect to resin flow through it during the mold-filling stage of the RTM
process.

Conclusion
After very lengthy analysis of Design optimization and
Multidisciplinary factors requirement analysis etc.
It is concluded that the composite-laminate door inner
panel analyzed in the present work should be fabricated
using Resin Transfer Molding (RTM)

The automotive door is
manufactured through various
processes like blanking, rolling
,forging, stamping and
assembly.
A door is made by assembling
together the inner panel , the
outer panel, the inner and
outer belt reinforcements, the
crash bar and the hinge pillar.
Manufacturing Process

Steps involved in manufacturing
• THE MANUFACTURING PROCESS OF CAR DOOR COMPRISES THE FOLLOWING STEPS:
• (1) CARRYING OUT INJECTION MOULDING ON A DOOR PANEL FRAMEWORK.
• (2) COATING HANDRAILS.
• (3) WELDING THE DOOR PANEL FRAMEWORK AND AN INSERT PANEL, AND WELDING
SOUND ABSORPTION COTTON.
• (4) ASSEMBLING A DOOR PANEL ASSEMBLY.

Process involved in car door manufacturing:-
•
•
TENDEM LINE PRESS
NEW TRANSFER PRESS

Steel Sheet Stamping
• STEEL DOORS ARE FIRST FORMED BY STAMPING THE INNER AND OUTER PANEL AND VARIOUS REINFORCEMENTS WHICH DIFFER WITH
THE SPECIFIC DOOR DESIGN. TWO GENERAL TYPES OF DOORS EXIST FROM THE LEVEL OF STAMPING.
• THE NUMBER OF STAMPING OPERATIONS WILL VARY ACCORDING TO THE DRAW RATIO AND THE COMPLEXITY OF THE OPENINGS AND
APERTURES ON THE PANEL. THE RANGE IS FROM LESS THAN FOUR PASSES TO MORE THAN SEVEN FOR A MAJOR BODY PANEL.
MODERNIZED PLANTS WILL USE SINGLE ACTION TRANSFER PRESSES WHILE MANY STILL USE THE TANDEM PRESS LINES.
1. FULL FRAME DOORS HAVING INTERNAL HEADER
SECTION. (POPULAR – VIEW IS GOOD + STYLISH)
2)HALF FRAME DOORS NOT HAVING INTERNAL
HEADER SECTION.

• TYPICALLY DOOR INNERS REQUIRE A REVERSE DRAW. THE FIRST DRAW IS TO CREATE THE LARGE CAVITY FOR ALL THE
DOOR HARDWARE AND THE REVERSE DRAW IS FOR ALL OF THE INDENTATIONS THAT ARE REQUIRED FOR ASSEMBLY
ACCESS AND FASTENING.
• TRANSFER STAMPING PRESS OR TANDEM PRESS ARE USED FOR THIS OPERATIONS.
• THE MAIN DIFFERENCE BETWEEN A TRANSFER PRESS AND A CONVENTIONAL H TYPE PRESS IS THE LARGER SIZE OF THE
FORMER ACCOMMODATES A PARTS FLOW THAT IS ORTHOGONAL TO THE FLOW IN THE LATTER.

• THE DEGREE OF AUTOMATION DEPENDS ON THE TYPES OF PRESSES AND THE AGE OF THE LINE.
• THE MAIN BENEFITS OF THE TRANSFER PRESS ARE THE REDUCTION IN LABOR DUE TO THE INTERNAL PARTS TRANSFER AND THE INCREASED
STROKE RATE. THERE IS ALSO A COST ADVANTAGE TO TRANSFER PRESSES IN THAT A SINGLE TRANSFER PRESS WHICH CAN RUN MULTIPLE
STATIONS WILL COST LESS THAN AN EQUIVALENT NUMBER OF PRESSES IN A TANDEM LINE.
• DOMESTIC STAMPING LINES TYPICALLY RUN BETWEEN 8 AND 12 STROKES PER MINUTE, WHILE JAPANESE STAMPERS TYPICALLY RUN THEIR
PRESSES AT 15 TO 18 STROKES PER MINUTE.
• ROLL FORMING IS LESS CHEAPER AND LESS COMPLICATED THAN STAMPING. HOWEVER ROLL-FORMING REQUIRES PLATES WELDED ON ITS END
FOR THE ATTACHMENT OF THE INNER PANEL.

•
•
•
•

•
EXPANDED POLYSTYRENE PROCESS.)
•
•
•

HOW THE R.T.M.
IS CARRIED OUT
• IMAGES
• TYPICALLY CONCEPT OF
FORGING PRESS.

•
•
•
•
•

•
•
•
•
•
•
•

•
•
•
•
• IT IS MOSTLY NOT USABLE PROCESS IN INDUSTRY .

In current automotive stamping
technology, there are two basic paths
that can be followed to arrive at the
final inner door panel.
(1) The First method is Part
Disintegration or Part Separation. In
this technique, each different section
of the blank is stamped separately and
then spot welded together in the
shape of the final part.
(2) The other possible method is the
Integration Method. In the integration
method, the part is stamped out of a
single blank.

As an solution to
estimating the cost of
metal and composite
parts assembly related
to the door,A model has
been developed.
The model is tailored to
door or liftgate-type
automotive assemblies
where small parts are
attached, through
welding or adhesive
bonding, to large
panels, two of which are
married and possibly
hemmed.
The model contains
enough information to
estimate cost.
associated with spot,
seam, and arc welding,
clinching, adhesive
bonding and curing, and
hemming.
The model optionally
can set the level of
automation used in
welding and adhesive
application, parts
loading and unloading
parts pick-and-place .

Painting is an
important and
costly process to
which all body
panel
components
must be
subjected.
The most unique
feature of the
model is the
assumption that
reject parts can
be repainted up
to 3 times before
scrapped and the
implication.
The vehicle body,
when fully built,
it is sent to the
paint shop.
The painting
operation starts
with a multistage
washing,
followed by a
zinc phosphating
treatment and
rinse.
The phosphating
treatment
promotes paint
adhesion and
improves
corrosion
resistance under
the paint layer
particularly in
the event that
the paint layer is
damaged.

• After the body has been painted, the next set of operations is the
addition of all the trim.
• Here there are basically two current scenarios as far as doors are
concerned.
• The case which has dominated domestic plants is the so called "doors
on" assembly, while more and more plants are adopting an approach
which the Japanese automotive manufacturers have developed called
"doors off".
• Another option is modular door assembly which is in many ways an
extension of the doors off" approach.

Doors On”
Assembly
• During “doors on” assembly door hardware
is attached to the door with the door on
the car.
• The advantage of keeping the doors on the
car is the elimination of the extra effort to
hang the doors twice, as well as
eliminating any of the complications of
making sure the same door removed from
a particular vehicle is returned to the same
one when fully trimmed.
• One of the disadvantages keeping the
doors on the vehicle while trimming them
is that the station size for every operation
must be large enough to accommodate
the entire vehicle with its doors open.
Doors Off”
Assembly
• Besides saving a great deal of floor space,
“doors off” assembly gives the workers much
better access to both the interior of the car
and to the door itself.
• The doors are positioned on the transfer
racks in such a way as to optimize access to
the many apertures of the door panel, while
also minimizing the possibility of damaging
the outer surface of the outer panel.
• Rehanging the doors after they are trimmed
does have an advantage in that it allows the
doors to be refitted into the body side
apertures with the full weight of the door
hardware.
• This can improve the overall fit of the door.

Doors are either brought to the body shop
from the adjacent welding hemming or
they are shipped from the stamping plant.
• Hinges are fastened, arc welded or both to
either the door or to the A pillar, and the door is
"hung" on the vehicle.
• The body side aperture is usually composed of
several welded sections and is therefore
"imperfect", whereas the door is essentially one
piece and is more dimensionally stable.
• However the door is more flexible than the
aperture and consequently it is "adjusted" to fit
the opening.

Conclusion
After Analyzing
different production
process which having
different influence on
end result.
After looking to all the
necessary factors we
can decide the process
to be used for particular
manufacturing.

References
• Design and impact Analysis of a Car Door
• MULTI-DISCIPLINARY DESIGN OPTIMIZATION OF A COMPOSITE CAR DOOR FOR STRUCTURAL PERFORMANCE,
NVH, CRASHWORTHINESS, DURABILITY AND MANUFACTURABILITY
• Impact analysis of side door of a car and bullet proof vest with material ‘SAM2X5-630’ using finite element
analysis
• Automotive Door Design & Structural Optimization of Front Door for Commercial Vehicle with ULSAB Concept
for Cost and Weight
REFERENCE:222112108MIT13(SCHOLAR)
• US2430437A - Method of making vehicle inner door panels
• CN104827676A - Manufacturing process for automobile door panel
• https://www.sciencedirect.com/topics/engineering/door-panel

Team Details
Name Roll No
Nagralawala Pulkit 19BME065
Jyotindra Naik 19BME066
Nem Mehta 19BME067
Nihar Shah 19BME068
Nikhilkumar Tiwari 19BME069
Nischal Mehta 19BME070
Padhariya Jay 19BME071
Shivam Padmani 19BME072
Parekh Krish 19BME073

Thank you for your Attention

Car door manufacturing in Real Industries

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