Design and static analysis of the outer rear door dies of Rajawali R2 SUV by using CATIA V5

The objective of the research is to design the outer rear door of Esemka Rajawali 2 by using reverse engineering method. Esemka car is one of the national cars being developed in Indonesia. Esemka Rajawali 2 has a Sports Utility Vehicle (SUV) model with 1.6L engine version, 1,597 cc inline DOHC. Reverse engineering method is used to obtain geometry data from the existing products and to reconstruct into three-dimensional drawing model. The three-dimensional model is used to design the mold or dies. Dies design is done by using CATIA V5 software. The process of die making plays an important role because it will be produced with a variety of car body components with particular desired shape. Design of a car body consists of various models, shapes, and construction. After the mold designs are completed, static analysis was done to determine the stresses that occur in the mold. This research has succeeded in modeling a three-dimensional model of the rear door using reverse engineering method. The dies design was successfully created using CATIA V5 software. From the static analysis results, by employing a maximum load of 50,000 N, the mold is still in a safe condition based on the yield stress of the used material.