The document provides guidelines for body-in-white (BIW) design and manufacturing. It discusses panel design considerations such as material thickness, stretching, and part splitting to maximize material utilization. Panel joinery guidelines recommend spot welds be loaded in shear and have a total material stack of 4-4.5mm. The BIW manufacturing process involves pressing panels, assembling the body, painting, trimming, and final assembly. Formability problems like fracturing and wrinkling can occur and are affected by material properties. Common steels used in BIW design are also discussed.
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The document provides guidelines for body-in-white (BIW) design and manufacturing. It discusses panel design considerations such as material thickness, stretching, and part splitting to maximize material utilization. Panel joinery guidelines recommend spot welds be loaded in shear and have a total material stack of 4-4.5mm. The BIW manufacturing process involves pressing panels, assembling the body, painting, trimming, and final assembly. Formability problems like fracturing and wrinkling can occur and are affected by material properties. Common steels used in BIW design are also discussed.
The document provides guidelines for body-in-white (BIW) design and manufacturing. It discusses panel design considerations such as material thickness, stretching, and part splitting to maximize material utilization. Panel joinery guidelines recommend spot welds be loaded in shear and have a total material stack of 4-4.5mm. The BIW manufacturing process involves pressing panels, assembling the body, painting, trimming, and final assembly. Formability problems like fracturing and wrinkling can occur and are affected by material properties. Common steels used in BIW design are also discussed.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online from Scribd
The document provides guidelines for body-in-white (BIW) design and manufacturing. It discusses panel design considerations such as material thickness, stretching, and part splitting to maximize material utilization. Panel joinery guidelines recommend spot welds be loaded in shear and have a total material stack of 4-4.5mm. The BIW manufacturing process involves pressing panels, assembling the body, painting, trimming, and final assembly. Formability problems like fracturing and wrinkling can occur and are affected by material properties. Common steels used in BIW design are also discussed.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online from Scribd
Download as pptx, pdf, or txt
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BIW Design
BIW Design Dos and Donts
Spots to be loaded in Shear The Material Thickness (All included) < ~4.00mm The Difference between the Thickness of welding panels : < 25% Check Distance between Two Consecutive spots Panel to be designed to have Max. Stretching. Thinning of Panels : ~10% Part to be designed to have minimum number of Dies. Panels to split in a manner to utilize maximum Steel Generally for big panels 60% utilization is Good
BIW Design Dos and Donts
Sufficient provision of Holes and Cutouts for Air Escape and Paint Drain. Weight Reduction Cutouts should be clubbed with the Access holes / Cutouts and Drains. Add Bird Beaks, Ribs to contain Spring back Avoid Stretch Flanges Corner Radii Min 2.5 * Depth (e.g. IngressEgress issue for Body Side)
Panel Design Guidelines Should not be odd and big in shape and size; handling issues. Size as per manufacturing facility available. Panel Split for maximum utilization of material, criticality of the area and manufacturing facility available. Generally for bigger panels 60% of material utilization is good. Sufficiently stretched Load Considerations. No area left un-stretched In areas which are mostly of geometrical continuity, Stiffener beads to be provided.
A maximum of 15% stretching is allowed in steel sheet drawing. Thinning < 10%. Depth of draw can be achieved by providing steps. Internal features (Local depressions) should have radius as big as possible. For deep draw panels, the number of draw should be as per manufacturing guidelines. Avoid providing any feature, in other than die tip angle, as this may lead to cam operation. If possible the trim edges of internal features should have some radius. (Sharp edge tools get damage soon)
Panel Design Guidelines
Panel Design Guidelines
Thickness of panels should be chosen as per the application. Do not increase the thickness of complete panel. Local reinforcement to be added as an when required. Latest trend is of Tailored blank.
To reduce the part weight, areas of least stress should be trimmed (Pockets created). The weight reduction pockets should be tried and clubbed for Tooling Access Holes, Air vent and Paint drain.
Panel Joinery Guidelines
Load on Spot weld to be in Sheer. Flange width to be as per manufacturing requirements (Tooling). For general purpose, 18mm flat is considered OK. There should not be more than three panel thickness stack for spot weld. CO2 weld and Brazing to be avoided. Joinery should be designed in a manner where no spot is on the A- class Surface. The joinery should be such that it counters the tolerance stack. Joinery should have sliding contact i.e. No joinery to be in locking condition.
Panel Joinery Guidelines
For bigger assemblies in docking - design gap should be kept. For Example between Side assembly and Underbody assembly, 1.00mm design gap is OK. The joinery to be sequenced to avoid any locking situation. There should not be a difference of more than 50% between two joining panels. To get better Spot strength, total material stack should be 4 to 4.5mm. The Serviceability aspects should be kept in consideration.
BIW Manufacturing Process
Press Shop Form the panels Presses Dies Checking Fixtures
Body Shop Assemble the panels Fixtures Welding Guns Checking Fixtures Metal Finishing tools Conveyers
Paint Shop Painting Body Pre-treatment Oven Baking Finishing
Trim Line Body Trimming I/P Fitment Seat Fitment Glasses
Final Assy Vehicle Rolldown Power Train Suspension Steering Fuel System Brakes Alignments
Painting Oven Baking Inspection
Trim Carpets
Testing Inspection
Formability Problems in Panels
Fracturing Buckling and Wrinkling Shape Distortion Oil Canning Undesirable Surface Textures (Orange Peel, Luder Lines or Stretcher Lines, Spangles etc)
Properties affecting the formability of material
r value Work Hardening Coefficient n value Resistance to thinning UTS Yield Point Elongation Uniform Elongation Total Elongation Yield Strength Hardness Punch Velocity Lubrication Chemistry
Steel used in BIW
Properties vary for the same material
From Supplier to Supplier From heat to heat From coil to coil From angle to angle with the rolling direction From one end of coil to other end of coil From one edge of coil to other
Design-Manufacture
Design-Manufacture
Exploded View of Automobile Body Panels
Door Inner Panel Panel A pillar Inner Hinge Reinforcement Rear Long Member Roof bow middle Roof bow rear Tail Gate panel
Sill Rear Inner
Shot gun panel
Bonnet Inner
Rear Floor Panel
Cowl Panel Hinge reinforcement B pillar inner Body Side Panel
