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Subject: Class-A Surface Guidelines

Contents
1) 2) 3) Phases of Class-A surface creation Class-A surface Definition Mathematical Requirements 3.1 3.2 3.3 4) Positional Continuity OR 0 - Order continuity Tangent Continuity OR 1 - Order continuity Curvature Continuity OR 2 - Order continuity 3 4 6 6 8 11 16 16 17 18 19 19 21 21 22 23 24 25 25 26 27 29 30 31 31 31 32 33 33 33 34 34 35 35

Curve Creation 4.1 4.2 4.3 4.4 4.5 Curve order Case study for curve creation Curve Redistribution Creation of Symmetry Curves Boundary curve creation

5)

Surface Creation 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 Criteria for surface creation Patch/Surface Parameterization Patch/Face Plan ISO-Curve distribution Patch/Face over building and trimming of Patch/Face Minimum Descriptive profile for surface creation Symmetry Criteria Transition Surface Surface Completeness Fillets

6)

Class-A surface verification 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 Patch properties Connectivity Analysis / G0 - Continuity Tangency Analysis / G1-Continuity Curvature Analysis Reflection Analysis Dynamic Highlight Analysis Absolute Curvature Analysis Mean Curvature Analysis Maximum and Minimum Curvature Analysis Guassian surface Analysis

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Subject: Class-A Surface Guidelines

7) 8) Curvature Analysis A case study Summary of Class-A Surface Standards 8.1 8.2 8.3 8.4 9) Classification of components and Applicable Class-A standards Class-A Standard-I Class-A Standard-II Class-A Standard-III 35 38 38 39 39 40 41 41 43 44

Manufacturing Criterias Case studies 9.1 9.2 9.3 Tips for manufacturability of hood Tips for manufacturability of fender Tips for manufacturability of Rear quarter panel

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Subject: Class-A Surface Guidelines

1)

Phases of Class-A surface creation

Figure 3.1-1

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Subject: Class-A Surface Guidelines

2)

Class-A surface Definition

Class-A surfaces and their requirements have a close relationship with the aesthetics of a product. The reflection of light plays a major role in surface appearance. If a surface does not posses certain described characteristics, Visual appearance of the product will get affected. Characteristics of Class-A surface can be classified into three major categories

Visual Characteristics
a) b) c) Aesthetic requirements Reflection, smoothness Style features as intended by Designer/Stylist

Mathematical Requirements
d) e) f) g) 0 order continuity (Positional Continuity / G0 Continuity) 1 order continuity (Tangent Continuity / G1 Continuity) 2 order continuity (Curvature Continuity/ G2 Continuity) 3 order continuity (Constant rate of change of curvature/ G3 Continuity)

Manufacturing requirements
h) i) j) k) l) Panels should retain their shape - proper stretching requirement should be taken care, Styled features should retain intended shapes, Feature lines like shoulder line or waist line on body side panel, feature lines on hood panel should retain their place (skidding), Bulge effect on flange lines should be avoided, Manufacturability of shapes (Forming of sheet metal, Moulded components) etc.

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Subject: Class-A Surface Guidelines

Defects which do not qualify for Class-A surface requirements Common visual defects, which can be attributed to the bad appearance of the surfaces m) n) o) p) q) r) Broken reflection lines - which will affect the homogeneous looks of the car body, Unintended highlights ( Unequal/Non parallel) Non-uniform transition highlights, Underflush and Overflush conditions Local dark spots in the middle of smooth surface - which may result in visual mismatch of colour, Effect of transparent surfaces like windshield, window glasses and long lenses on surface Curvatures, s) Local bright -unintended highlights, spots etc.

Common Mathematical defects found in surfaces t) u) v) w) x) y) z) aa) bb) Connectivity problems like gap and overlapping along common edge, Tangency problem between two adjacent surfaces along common edge, Curvature discontinuities between surfaces, Bad parameterization, Bad distribution of ISO-parametric curves, Topological problems, Twisted patches, Local depressions and bumps, Triangular patches, etc.

Common Manufacturing defects found in surfaces For sheet metal panels cc) dd) ee) ff) gg) hh) ii) Flat surface inadequate lensings, Possibility of skid marks, Bulge at flange lines, Sharp, acute trim lines and shut lines, Draw depth and corner radii mismatch, Under flush and Over flush co-ordination, Local depressions and bumps etc.

For Plastic components jj) kk) ll) Shrinkage marks, Molding direction, Undercuts,

mm) Seen parting lines, nn) oo) pp) Insufficient draft angle for given textures, Inadequate lensing, Warping etc.

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Subject: Class-A Surface Guidelines

3)

Mathematical Requirements
3.1 Positional Continuity OR 0 - Order continuity
Surface are said to be having Positional Continuity, when they posses the following characteristics Adjacent faces/surfaces are sharing a common edge, Gap between them is less or equal to the recommended tolerance limit along the common edge They are curvature continuous within Refer images for more information

Surfaces are smooth

Note: 1) Observe the smooth variation in reflection of light. 2) Observe the presence of sharp reflection line in the middle of the surface

Image 3.1-1

Sharing Common edge

Image 3.1-2

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Subject: Class-A Surface Guidelines

Curvature Continuous within Share a common edge Gap between them along the edge is within tolerance limit

Note: Angle between the Normals to the surface or curve on a point laying on the common edge is not within the set tolerance limit.

Image 3.1-3

Dynamic reflection highlights Analysis Result Note the broken Highlights at Common edge

Image 3.1-4

Mean Curvature Analysis result

Image 3.1-5

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Subject: Class-A Surface Guidelines

Refer images below for allowable errors for acceptance of surface for Positional continuity

Image 3.1-6 Industry Standard Examples DCX Value 0.02 GM 0.025 FORD 0.02 BERTONE 0.01 TTL 0.01

Note: Some values given here are based on the inputs from un-official source Image 3.1-7

3.2 Tangent Continuity OR 1 - Order continuity

Surface are said to be having Tangent Continuity, when they posses the following characteristics. Adjacent faces/surfaces are sharing a common edge. Gap between them is less or equal to the recommended value along the common edge. Angle between the normals at any common point on common edge is within in the set tolerance value. They are curvature continuous within. Refer below images for more information

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Subject: Class-A Surface Guidelines

Surfaces are smooth Note: 1) Observe the smooth variation in reflection of light. 2) Observe the absence of sharp reflection line in the middle of the surface in comparison with Figure for G0 continuity.

Image 3.2-1

Sharing Common edge

Image 3.2-2 Note: Curvature Continuous within Gap between them is within the recommended tolerance limit Share a common edge

Angle between the normals to the surface or curve at a point laying on the common edge is within in the set tolerance value.. Observe the sudden change in curvature value between the normals to the surface or curve at a point laying on the common edge. Image 3.2-3

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Subject: Class-A Surface Guidelines

Dynamic reflection highlights Analysis Result

Note the abrupt deviation in highlights at Common edge.

Image 3.2-4

Mean Curvature Analysis result

Image 3.2-5 Refer image below for allowable errors for acceptance of surface for Tangent continuity

Industry Standard Examples

DCX Value 0.05 GM 0.05 FORD 0.07 BERTONE 0.1 TTL 0.05

Note: Some values given here are based on the inputs from un-official source

Image 3.2-6

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3.3 Curvature Continuity OR 2 - Order continuity

Surface are said to be having Curvature Continuity, when they posses the following characteristics. qq) rr) ss) tt) uu) Adjacent faces/surfaces are sharing a common edge. Gap between them is less or equal to the recommended value along the common edge. Angle between the normals at any common point on common edge is within in the set tolerance value. Variation in curvature value at two points on same curve on surface is within specified value. They are curvature continuous within.

Refer images for more information

Surfaces are smooth Note: 1) Observe the smooth variation in reflection of light. 2) Observe the uniform dispersion of light in the reflection zone in the middle of the surface in comparison with Figure for G1 continuity.

Image 3.3-1

Sharing Common edge

Image 3.3-2

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Subject: Class-A Surface Guidelines

1) Curvature Continuous within 2) Gap between them is within in the tolerance limit 3) Share a common edge Note: Angle between the normals to the surface or curve at a point laying on the common edge is within the set tolerance value.

Image 3.3-3

Dynamic reflection highlights Analysis Result Note the smooth deviation in highlights at Common edge

Image 3.3-4

Mean Curvature Analysis result

Image 3.3-5

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Subject: Class-A Surface Guidelines

Refer image below for allowable errors for acceptance of surface for curvature continuity

Industry Standard Examples

DCX Value 0.001 GM 0.001 FORD 0.005 BERTONE 0.01 TTL 0.001

Note: Some values given here are based on the inputs from un-official source

Image 3.3-6 Constant Rate of Change of Curvature Continuity OR 3 - Order continuity Surface are said to be having Constant rate of change of curvature Continuity, when they posses the following characteristics Adjacent faces/surfaces are sharing a common edge, Gap between them is less or equal to the recommended value along the common edge Angle between the normals at any common point on common edge is within in the set tolerance value. Variation in curvature value at two points on same curve on surface is within specified value. Distant between two points on curves for which the change of curvature occurs has to be same for all point on the curves. Refer images for more information

Surfaces are smooth Note: 1) Observe the smooth variation in reflection of light. 2) Observe the further improvement in uniform dispersion of light in the reflection zone in the middle of the surface in comparison with Figure for G2 continuity.

Image 3.3-7

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Subject: Class-A Surface Guidelines

Sharing Common edge

Image 3.3-8

Curvature Continuous within Gap between them is within the set tolerance value

Share a common edge Note: Distance between points on curve on the surface For which curvature changes is constant

Image 3.3-9

Dynamic reflection highlights Analysis Result

Note the smooth deviation in highlights at Common edge

Image 3.3-10

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Subject: Class-A Surface Guidelines

Mean Curvature Analysis result

Image 3.3-11

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Subject: Class-A Surface Guidelines

4)

Curve Creation

Creation of a curve plays a very important role in the process of Class-A surface creation. The quality of the curve dictates the quality of the surface. Criteria for curve creation Curves should be of minimum required order as far as possible (preferred order-3 maximum order is based on the software being used) Curves should support or facilitate the adjacent curve nature Avoid curve with inflection unless they are a must Split the curve as far as possible to avoid unnecessary tension Give a close look to curve descriptors while creating curves

4.1 Curve order

Every curve has a degree - a mathematical concept referring to the degree of the polynomial that defines the curve. The degree is generally one less than the number of points in the curve descriptor. For this reason, you cannot have a curve with lesser points than the degree of the curve. A higher degree curve is stiffer, in the sense that you have to move its poles a long way to produce any appreciable change in the shape of the curve. Lower degree curves are more pliable, and tend to follow their poles much more closely. However, it is recommended to use curves of degree 3. Higher degree curves are more likely to contain undesirable oscillations. You should use lower degree curves whenever possible (3, 4, and 5). Use the default degree of three (3) unless you have some good reason for doing otherwise. The degree of a single segment curve is dependent on the number of its specified points. Refer images for more information

Curve of Degree 3, and Class 4 Note: Curves of this type are easier to handle; for any change made to the curve by moving its pole, the change in shape will be monotonic in nature across the curve.

Image 4.1-1

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Subject: Class-A Surface Guidelines

Curve of Degree 5, and Class 6 Note: Curves of this type are not easier to handle; for any change made to the curve by moving its pole, the change in shape may not be monotonic in nature across the curve because of high parameterisation of the curve. Shape of the curve is exactly similar in shape and size to the curve shown in the image.

Image 4.1-2

Curve of Degree 6, and Class 7 Note: Shape of the curve is exactly similar in shape and size to the curve shown in Image 4.1-1 and Image 4.1-2 on page No. 16 Observe the bad parameterisation of the curve, which is not desirable for Class-A surface creation.

Image 4.1-3

4.2 Case study for curve creation

While creating a curve from digitised points, it is essential to give a close look to the parameter distribution of the curve. In the given example, even though curves are exactly similar in shape, size and position they are not identical in their mathematical properties.

Curve Degree 7, Class 8 Note: Observe the curve parameter distribution, which is erratic. Curve is of very high degree and class, which is not recommended. Observe the adulations in curvature variation as seen from the curvature normals.

Image 4.2-1

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Curve Degree 3, Class 4 Note: Smooth variation in curve parameter distribution. Desired shape is achieved by a curve of lower degree and class, which is highly recommended. Observe the curvature variation as seen from the curvature normals. The variation in this case is smooth as compared to the earlier case.

Image 4.2-2

4.3 Curve Redistribution

Curve of Degree 9 and Class 10 Note: Observe highly haphazard distribution of curve parameters. Curve created by software tool from digitized data.

Image 4.3-1

Curve of Degree 9 and Class 10 Note: Observe smooth and monotonic variation in distribution of curve parameters Curve created by using smoothing technique. optimization and

Image 4.3-2

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Curvature analysis of the Curve

Image 4.3-3

4.4 Creation of Symmetry Curves

For curves, which are to be used in creating surfaces for panels like Hood, Windshield, Roof, Trunk lid and Front and rear bumpers, special care has to be taken while creating the curves and surfaces. While creating symmetry curves check the following properties in the curve 2) 3) 4) 5) 6) Curvature continuity value at the plane of symmetry should be Zero Tangency continuity at plane of symmetry should be Zero Positional continuity at plane of symmetry should be Zero It is recommended to have curves of Degree 3,5 and Class 4,6 It is not recommended to have a curve node at plane of symmetry.

Symmetry Curve Note: Observe the absence of curve node at plane of symmetry, most of the times this condition automatically ensures G0, G1 and G2 continuity.

Figure 4.4-1

4.5 Boundary curve creation

While creating end boundary curve for patches, check for the following characteristics in the curves. Both curves should be of Same class and degree Similar nature in mathematical parameterisation. Change in curve parameter distribution should be monotonic in nature. In the absence of above characteristics, chances of internal surface distortions are very high.

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End boundary curves Note: Observe polynomial distribution of the curves.

Image 4.5-1

End boundary curves Note: Observe the change in the polynomial distribution of the curves and the change in the curve position due to this.

Image 4.5-2

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5)

Surface Creation

As explained in the earlier chapter, quality of the surface plays major role in aesthetics of the product, it is very important we take a lot of care while creating a surface. Apart from basic requirements like positional continuity, tangent continuity and curvature continuity, following criterias has to be given due consideration.

5.1 Criteria for surface creation Patch/Surface parameterisation

Polynomial representation of a surface is defined by a network of lines and points, These control points or poles are distributed over sections.

Patch/Face Plan
Division or splitting of patches to create features in surfaces

ISO-curve distribution Surface over-building and trimming of surface

Creation of extra surface beyond the required area for component design

Minimum descriptive profiles for surface creation

Use minimum required number of end boundaries and internal support profiles to define a patch or surface.

Symmetry criteria
Guidelines for creation of symmetric surfaces.

Transition surface creation

Joining of two main surfaces with another surface.

Surface or face tension

High concentration of patch descriptors in a local area of a patch/face, because of maximum curvature.

Surface completeness
Completely defined surface in all respects, by mathematical definitions.

Fillets

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5.2 Patch/Surface Parameterization

Patch or surface is said to be of good quality when it has the following characteristics a) b) c) d) Good distribution of patch descriptors or vertices Patch should not possess any kinks in the descriptors pattern. Minimum number of descriptors Uniform variation in descriptor pattern

Refer Images for more information

Good patch/face descriptors Note: Minimum number descriptors. of patch

Smooth variation in light reflection on the shape.

Image 5.2-1

Bad patch/Face descriptors Note : High number of patch descriptors. Kink in one of the descriptors.

Image 5.2-2

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Subject: Class-A Surface Guidelines

Patch/Face Plan Important aspect of good surface creation is patch plan. It is important for the surface creator to plan the patch/face split to achieve good quality in surfaces. Good patch/face plan goes a long way in helping creation of good merging of main surfaces, creation of features, termination of features, corners, transition surfaces, bends etc. only experience can help in deciding patch/face plan Refer Images for more information

Shaded image of fender

Image 5.2-3

Patch/Face plan of fender

Image 5.2-4

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Subject: Class-A Surface Guidelines

5.3 ISO-Parametric Curve distribution

Distribution of ISO-curves is the primary indication of a good quality patch.

Bad ISO-curve distribution Note: Distribution of ISO-Parametric curves is not homogeneous May have local surface tension. Smooth variation is not there. Curves are bent and Curves are straight.

Image 5.3-1

Good ISO-curve distribution Note: Smooth variation distribution in ISO-Parametric curve

Image 5.3-2

Difference between good and bad ISO-curve distribution of patch/face Note: Path with Bad ISO-parametric curve distribution is shown in dotted lines. Observe the difference in shorter boundary condition between two patches

Image 5.3-3

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Subject: Class-A Surface Guidelines 5.4 Patch/Face over building and trimming of Patch/Face 5.5 Minimum Descriptive profile for surface creation
While creating a patch, use minimum required number of end boundaries and internal support profiles to define a face or patch. Try to create the main patches bigger than required area, Later trim them to a desired shape using trimming profiles. Note: e) f) Use of high number of profile to define the patch may result in bad quality. Patch with minimum number of constraints posses characteristics like, good distribution of ISO-parametric curves, Better parameterization.

Refer image for more information

Defining profiles

Patch over building

Trimming profiles

Image 5.5-1

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Subject: Class-A Surface Guidelines

5.6 Symmetry Criteria

While creating surface for Hood panel, Roof, Trunk lid , windshield, Rear window and tailgate, normal practice is to create one side of the panel, for other side surface is reflected. While doing so, following criteria should be fulfilled at plane of symmetry (XOZ-Plane,Y=0) g) h) i) j) Positional Continuity Tangency and curvature continuity Curvature variation No directional variation

Symmetry Plane

Curvature of good symmetry patch Note: In this case Positional, Tangency, and curvature continuities are fulfilled. Observe the length and shape variation of curvature normal in the marked area.

Image 5.6-1 Symmetry Plane Curvature of bad symmetry patch Note: In this case only Positional and Tangency continuities are fulfilled. Observe the length and shape variation of curvature normal in the marked area.

Image 5.6-2

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5.7 Transition Surface

Case study for the use of transition surface and its advantages

Front fascia with transition surface

Front fascia without transition surface Figure 5.7-1

C M T C

Observe Two main surfaces marked M are joined by using transition surface marked C Two main corner surfaces marked C are joined by using transition surface marked T

Observe Concept of using transition surfaces is not applied while creating the surface

Figure 5.7-2
Uniform ISO-curve distribution

Irregular

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Subject: Class-A Surface Guidelines

Observe Uniform distribution of ISO-curves between main surface and transition surfaces. This is the result of using a transition surface, which gives more control over creating corner and joining surfaces. Observe Irregular distribution of ISO-curves in main surface.

Figure 5.7-3

Observe Uniform variation in ISO-curve shapes. Synergy in variation of gaps between ISO-curves distribution.

Observe Irregular variation in ISO-curve shapes. Irregular variation of gaps between ISO-curves distribution.

Figure 5.7-4

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5.8 Surface Completeness

Surface should be complete in all respects. Check for the following imperfections like incomplete filleting operation, untrimmed patches, undefined corners, etc. Refer images for further reference:

Observe untrimmed bottom patch

Untrimmed patch Figure 5.8-1

Observe marked area

Incomplete corner and Fillet Figure 5.8-2

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5.9 Fillets
While creating fillets for joining two surfaces/patches, avoid using circular / cylindrical fillets. This kind of fillets, will not guarantee a good reflection effect because of the sudden change in curvature at the joining lines. To improve the aesthetic effects, it is suggested to use conical blending, which is available in softwares like CATIA and EUCLID-3. Limit the use of mechanical blending to following areas 1) 2) Unseen areas like corners, Flange line blending, Joggles on flanges etc. Less important areas, like where fillet radius required R is < 5.

Mechanical Filleting

Image 5.9-1 Conical Filleting

Conical Filleting

Image 5.9-2

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Subject: Class-A Surface Guidelines

6)

Class-A surface verification

6.1 Patch properties

ISO-parametric Curve distribution/Patch parameterization

Polynomial representation of a surface, defined by a network of lines and points, called control points or poles. These points are distributed over sections.

Image 6.1-1

6.2 Connectivity Analysis / G0 - Continuity

Global connectivity analysis This method is used for finding out the gaps in surface topology connections. Connectivity analysis result for hood surface is shown in following images.

Image 6.2-1

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Subject: Class-A Surface Guidelines

Green lines Global connectivity analysis Wire frame model of the hood surface, shown before submitting for connectivity analysis Note: Observe green lines in surface

Image 6.2-2 Global connectivity analysis Green lines Red lines Result of connectivity analysis Gaps more than 0.05 are shown in red colour Gaps less than 0.05 and free edges are still shown in green colour. Note: 1) Threshold value for connectivity analysis used in this case is 0.05. Method of result display software dependent. is

2)

Image 6.2-3

6.3 Tangency Analysis / G1-Continuity

Global Tangency Analysis This method is used for finding angle between two adjacent patch along a common edge. Note: 1) 2) 3) Threshold value for connectivity analysis used in this case is 0.05. Observe magenta coloured lines in surface. Method of dependent. result display is software

Image 6.3-1

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Subject: Class-A Surface Guidelines 6.4 Curvature Analysis

Surface/Patch curvature analysis of a curve Laying on a surface for uniform variation in curvature Note: Curvature analysis of roof is shown.

Image 6.4-1

6.5 Reflection Analysis

Display of the reflection lines created on a patch by a line of light of infinite length

Image 6.5-1

6.6 Dynamic Highlight Analysis

This action is used to detect local flaws on supporting surfaces and to check that surfaces are smooth. Highlights are similar to reflection lines with the difference that highlights do not depend on the user's view point. It is a simplified reflection model. As with reflection lines, highlights magnify discontinuities on a supporting surface.Tangent plane discontinuity between two patches in a surface is shown up as discontinuous highlights. Discontinuous highlight tangents shows curvature discontinuity between two patches (sharp angle where the contours join). Highlights have a lower order of continuity than the surfaces they are traced on.

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Subject: Class-A Surface Guidelines

Display of the Dynamic Highlights created on a roof surface

Image 6.6-1

6.7 Absolute Curvature Analysis

It is used to detect the surface areas where the surface is locally almost flat, that is when the absolute curvature is almost null.

Image 6.7-1

6.8 Mean Curvature Analysis

The utmost values appear where the surface is the most warped. Mean is largely used to detect irregularities on the surface. A minimal surface is characterized by a null mean curvature.

Image 6.8-1

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Subject: Class-A Surface Guidelines 6.9 Maximum and Minimum Curvature Analysis

The geometric construction of main curvatures is the following: let be a plane containing the normal to the surface in a given point. This plane cuts the surface along a curve that has a given curvature in this point. If this plane rotates around the normal, the curvatures of the curves of intersection with the surface will vary between two utmost values. These two values are the main curvatures

Image 6.9-1

6.10 Guassian surface Analysis

It describes the local shape of a surface in one point: If it is positive, the point is elliptic, i.e. the surface has locally the shape of an ellipsoid around the point. If it is negative, the surface is hyperbolic in this point, i.e. the local shape is a horse saddle. If it is null, the surface is parabolic in this point, i.e. one of the two main curvatures is null in this point. Ps: The cone and the cylinder are two surfaces where all points are parabolic.

Local depression on a roof surface Shown using Guassian surface analysis

Image 6.10-1

7)

Curvature Analysis A case study

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Subject: Class-A Surface Guidelines

Good roof surface Observe Smoothness of surface Uniform Dispersion of light in reflection zone Defective roof surface Observe Smoothness of surface Uniform Dispersion of light in reflection zone Image 6.10-1

Good roof surface Observe Smoothness of Dynamic highlights Uniform variation in dynamic highlight line shapes Uniform Gap between dynamic highlight lines

Defective roof surface Observe Smoothness of Dynamic highlights Uniform variation in dynamic highlight line shapes Non-uniform Gap between dynamic highlight lines Image 6.10-2

Good roof surface Mean curvature analysis result

Defective roof surface Mean curvature analysis result Image 6.10-3

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Subject: Class-A Surface Guidelines

Good roof surface Observe absence of local depression in Guassian curvature analysis result

Defective roof surface Observe presence of local depression in Guassian curvature analysis result Image 6.10-4

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8)

Summary of Class-A Surface Standards

8.1 Classification of components and Applicable Class-A standards

SHEET METAL PANELS

External Panels

Internal Panel

External Seen

External Unseen

Internal Seen

Internal Unseen

Class A Standard I

Class A Standard II

Class A Standard II

Class A Standard III

Figure 8.1-1

Plastic Trims

External Panels

Internal Panel

Painted/Textured Seen

Painted/Textured Unseen

Painted/Textured Seen

PaintedTextured Unseen

Class A Standard I

Class A Standard II

Class A Standard II

Class A Standard III

Figure 8.1-2

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8.2 Class-A Standard-I

Applicable For
1) 2) External seen Sheet metal panels Exterior seen painted plastic trims

Characteristics
G0 Positional Continuity G1 Tangency Continuity G2 Curvature Continuity G3 Constant rate of changes of curvature Patch descriptors ISO-curve distribution Fillets Manufacturability criterias Dynamic highlights Table 8-1 0.01 0.05 0.001 ---

Standards

Refer Section 5.2 Refer Section 5.4 Mechanical Fillets for < 5R * Refer Section 9 Refer Section 6.6

8.3 Class-A Standard-II

Applicable For
1) 2) 3) 4) Exterior seen plastic textured trims Interior seen plastic textured trims Interior seen plastic textured trims Interior seen sheet metal panels

Characteristics
G0 Positional Continuity G1 Tangency Continuity G2 Curvature Continuity Patch descriptors ISO-curve distribution Fillets Manufacturability criterias Dynamic highlights Table 8-2 0.02 0.05 0.02

Standards

Refer Section 5.2 Refer Section 5.4 Mechanical Fillets for < 5R * Refer Section 9 Refer Section 6.6

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8.4 Class-A Standard-III

Applicable For
1) External unseen areas of Sheet metal panels Example: Areas of Body side panel hidden after door closer, Lamp pockets, Mirror pockets on door frame, Etc. Unseen painted and textured plastic trims

Characteristics
G0 Positional Continuity G1 Tangency Continuity G2 Curvature Continuity Patch descriptors ISO-curve distribution Fillets Manufacturability criterias Dynamic highlights 0.02 0.1 0.05

Standards

Refer Section 5.2 Refer Section 5.4 Mechanical Fillets for < 4R * Refer Section 9 Refer Section 6.6

2)

Note: 3) 4) 5) 6) 7) 8) 9) Take care for not changing styling intent shapes and features in all above cases. Seen means - areas which are coming in lines of direct visual angle of a person standing next to the car, and sitting inside the car. Unseen means - areas which are not coming in lines of direct visual angle of a person standing next to the car, and sitting inside the car.

* In case of fillet values take care for minimum exterior and interior projection regulations.
Decide the maximum allowed deviation for Class-A surface creation from Digitised data for each model. Take the approval from Styling department in case of deviation from digitized data. Observe for regulatory requirements during the creation of Class-A surfaces. Example: Minimum external and internal projection regulations.

10)

At the stage of design verification, changes done on styled surface with respect to the Stylingfreeze should be documented and agreed upon.

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9)

Manufacturing Criterias Case studies

Objective of this section is to lead stylist or product engineers through the manufacturing process for sheet metal. Cases listed in this section of the documents are only for reference and knowledge of the stylist and product engineers. The cases explained here are not to be considered as guidelines. While designing the panels for manufacturability, proper attention needs to be given for following aspects of sheet metal components. Panels should retain their shape after stamping process, for the same proper stretching requirement should be taken care, Styled features should retain intended shapes, For example, Feature lines like shoulder line or waist line on body side panel, Feature lines on hood panel should retain their place. Bulge effect on flange lines should be avoided. In the same way, while designing plastic trims, care should be taken care to avoid warping of panels at free ends, shrinkage effect on the areas where internal ribs are provided for strength purpose.

9.1 Tips for manufacturability of hood

Shaded image of hood panel Image 9.1-1

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Subject: Class-A Surface Guidelines

Figure 9.1-1

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Subject: Class-A Surface Guidelines

9.2 Tips for manufacturability of fender

Shaded Image of Front fender Left Image 9.2-1

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Subject: Class-A Surface Guidelines

In depth D is not constant, give constant offset depth d to avoid bulge effect along flange line

Indicator Lamp depression depth to be kept within 2-3 mm

50R Minimum Radius to be kept

Feature line near wheel arch, high risk of skidding, if the panel is stretched to the maximum limit

Incase of radical under sweeping at rear of wheel arch, Reduce the flange with to minimum possible

Figure 9.2-1

9.3 Tips for manufacturability of Rear quarter panel

Keep the feature line away from flange line by minimum 25mm, to avoid skidding effect. Do not leave the feature line sharp for avoiding local stretching, on the fillet. Complete them by using conical filleting option with maximum possible ratio Flange Line

Minimum angle suggested between the two surfaces creating this kind of feature is 20

Figure 9.3-1

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Subject: Class-A Surface Guidelines

Figure 9.3-2

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Subject: Class-A Surface Guidelines

Figure 9.3-3