Posted: March 11th, 2022

Automobile Door

Automobile Door
A labeled Part

Over the years, artists such as Leonard De Vinci have worked on how to design an automobile. In the late seventeenth century, France, Nicholas Joseph Cugnot, Karl Friedrich, and Karl Benz worked on creating automobiles and looking for ways to propel them. Additionally, the innovators were more concerned with having an automobile engine but did not focus on accessibility, safety, and privacy (Sharma, Sahu, and Bhosale, 2017). It is surprising that in the early eighteenth century, most cases, such as the Ford Model T’s, was made without a door, and passengers had to protect themselves from falling using safety glasses. However, doors were first made in the early nineteenth century, although they were cumbersome, which used a lot of energy to close, ad open compared to the current doors. The automobile took the lighter and heavy doors, which users quickly broke due to mishandling. Automobile doors, however, are opened by swinging out and hinged at the front edge.

Materials, and Manufacturers Specifications
The material and its specifications used to manufacture the parts have developed and continue to advance significantly besides various gadgetry that adds safety, such as the door switches, the door brakes, keyless doors, carbon steel panels, and warning doors (Sun, Chen, and Tao, 2020). The automobile doors are either made from steel, aluminum, magnesium, fiberglass, and plastic. The doors are, however, fitted with some metal on the inside to enhance strength and safety. However, the automobile door’s outer skin is either made of steel or aluminum depending on the quality of the car, some made of carbon fiber, and others of fiberglass (Renzi, Leali, and Di Angelo., 2017).
On the other hand, the doors are fitted with steel infrastructure from the inside of the door, improving safety and increasing the absorption for the side-impact crash. Most high-end brands, such as Audi, infinity, and others, use aluminum instead of steel because aluminum is lighter and does not readily corrode. However, in automobile cars, lighter materials are used instead of heavy materials and materials with advanced mechanical properties(Sun, Chen, and Tao, 2020). Most of the time, the manufacturers use the ultra-light steel autobody (ULSAB), which reduces weight reduction as a significant problem. The manufacture, however, opts for the use of hydro-forming techniques, which are and the tailor welded blank(TWB). The steel, however, is considered a suitable material, especially in reducing the total weight of the door.
On the other hand, the use of steel saves on material, prevents issues, such as overlapping joints, and assists in meeting carbon iv targets by reducing carbon emissions. Other materials used include boron, aluminum, Silicon, Phosphorous, Titanium, Niobium, and Aluminium. The materials provide elongation, tensile strength, and yield strength of the inner panel (Sun, Chen, and Tao, 2020). The tailor welded blanks made from steel sheets help prevent water leakage issues because the sheets are of different strengths, coating, and thickness.
The manufacturing processes
The manufacturing process f automobile doors follows several steps. One, injection molding on the door panel framework, coating handrails, welding the door panel framework, welding sound absorption cotton, assembling the process, and using an automatic welding machine (Renzi, Leali, and Di Angelo., 2017). However, due to the increasing development of automobiles, the industries have improved on their manufacturing methods. The manufacturing process consists of several steps or processes, the door-plate skeleton injection molding, the handbrake coating, the door plate skeleton acoustical cotton welding, and a door plate general assembly. Acoustic cotton welding uses an automatic welder and supersonic welding functions, where the automatic welder improves operating efficiency and reduces the human resources used in the process (Renzi, Leali, and Di Angelo., 2017). Additionally, the machine increases the welding quality, decreases the number of human injuries, and offers environmental protection. Today, the manufacturing industries use several quality and cost-effective materials in making automotive door parts, For instance, mild steel, the high strength steel(HSS), the advanced high strength low alloy, the ultra high strength steel the born, and magnesium, and the reinforced plastic carbon fiber.
The process focuses not only on the internal design but also on the exterior design and works on the door’s durability, the closing door sound, crash safety, and quietness. On the other hand, the doors are made according to the owner’s specifications, such as the design, functioning, and performance. The injection molding machine assists in making the door interior, and other parts, especially where the manufacturers customize an injection molding solution of the vehicle (Renzi, Leali, and Di Angelo., 2017). The process entails the door hanging process, the door fitting process, where the door hanging process involves hanging the door to the front hem of the rear door, which assists in gap control.

The door fitting process assists in acquiring the door’s desired appearance and improving the dimensional quality of the door. The door hanging and fitting process, however, face some issue, such as lack of a procedure for door hanging fixture adjustment, lack of knowledge concerning the correction of the gap deviation, and the inconsistency of the door fitting, which takes place through the use of a frequent fixture adjustment (Renzi, Leali, and Di Angelo., 2017). However, different manufacturing processes of the automobile door parts affect the parts’ quality, hence leading to dimensional variations. However, the quality of the automobile door parts can be summarized into the body opening dimensions, the door dimensions, and considering the door’s relative position according to the body opening.
The leading cause of fitting issues, flushness, and uneven gaps in automotive door parts include the dimensional variation of the door and size. However, the straightness variation of the opening and the width affect the automobile doors’ dimensional quality (Sharma, Sahu, and Bhosale, 2017). New methods have been developed in manufacturing processes to avoid issues during the manufacturing process, which assist in dealing with the current issues that face the doors’ development. However, the process should follow the national standards-setting bodies NSB regulation, such as the OEMs fleet fuel economy and the Corporate Average Fuel Economy (CAFE) standards. The automotive door parts’ current manufacturer is based on three perspectives: the structure of the machinery side, the transformation side, and the procedural side.
Suggestion for Improvements
The manufacturing process has mainly improved, especially on the materials and machines used to make automobile cars (Sharma, Sahu, and Bhosale, 2017). The process of improving safety and reducing automobile doors’ and cost involves using more advanced, better, and cost-effective materials to reduce carbon emission, fuel economy, and are cost-effective. The manufacturing industries use materials such as composite materials, magnesium, and aluminum that improve the quality and safety of automobile parts. On the other hand, the manufacturing industries focus on intelligent mobility, improved manufacturer processes, and alternative vehicle propulsion systems. Some of the innovative manufacturing processes that will improve the quality of automotive doors and reduce cracking include the use of hot-formed steel, which improves the flexibility and improves the quality of complex shapes.
Additionally, the high-pressure thin-walled aluminum dies casting requires high temperature and pressure for melting and solidification. On the other hand, the use of resin transfer molding, which promotes the formation of high-strength automotive door parts. Additionally, 3D printing helps manufacturers develop molding, development of high strength plastic, aluminum, and other more vital metals. The hot forming process is a convenient manufacturing process that makes materials lighter and stronger, especially steel (Sharma, Sahu, and Bhosale, 2017).
The manufacturing industries’ future requires the industries to use laser spot welding to create fuses, the flow drill screws, the tailor welded, adhesives, bolting, and self-piercing rivets. The enabling factors that will promote the need for the advanced manufacturing industry in the future include the need for autonomous vehicles, reduction of the fuel economy, and promotion of vehicle emission reduction, the increasing rate of fuel economy, promotion of electric power train, and addition of content which makes the materials lighter(Sun, Chen, and Tao, 2020). However, the manufacturing industries work at preventing and reducing the current issues faced in making automotive doors and the durability of the doors. For instance, the cost, cycle time, mixed material joining, thermal expansion, supply chain, repair, talent gap, and corrosion of the parts are prevalent, especially when the doors are not fitted with materials that reduce water absorption.

References

Renzi, C., Leali, F., & Di Angelo, L. (2017). A review on decision-making methods in engineering design for the automotive industry. Journal of Engineering Design, 28(2), 118-143.
Sharma, S. K., Sahu, A. K., & Bhosale, S. (2017). Multidisciplinary Design Optimization of Automobile Tail Door (No. 2017-01-0251). SAE Technical Paper.
Sun, L. J., Chen, H. X., & Tao, G. X. (2020, February). The Application of Interpolation Method in the Design of Automobile Door Curve. In 2020 12th International Conference on Measuring Technology and Mechatronics Automation (ICMTMA) (pp. 159-163). IEEE.

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