Page 1 of 45

Subject: Class-A Surface Guidelines

Contents
1) Phases of Class-A surface creation....................................................................................................................3 2) Class-A surface Definition..................................................................................................................................4 3) Mathematical Requirements..............................................................................................................................6 3.1 Positional Continuity OR 0 - Order continuity..............................................................................................6 3.2 Tangent Continuity OR 1 - Order continuity.................................................................................................8 3.3 Curvature Continuity OR 2 - Order continuity...........................................................................................11 4) Curve Creation..................................................................................................................................................16 4.1 Curve order..................................................................................................................................................16 4.2 Case study for curve creation......................................................................................................................1 4.3 Curve Redistri!ution ...................................................................................................................................18 4.4 Creation of "y##etry Curves......................................................................................................................1$ 4.% &oundary curve creation..............................................................................................................................1$ ) !urface Creation...............................................................................................................................................21 %.1 Criteria for surface creation .......................................................................................................................21 %.2 Patc'("urface Para#eteri)ation..................................................................................................................22 %.3 *"O-Para#etric Curve distri!ution..............................................................................................................24 %.4 Patc'(+ace over !uilding and tri##ing of Patc'(+ace...............................................................................2% %.% ,ini#u# -escri.tive .rofile for surface creation.......................................................................................2% %.6 "y##etry Criteria........................................................................................................................................26 %. Transition "urface........................................................................................................................................2 %.8 "urface Co#.leteness..................................................................................................................................2$ %.$ +illets............................................................................................................................................................30 6) Class-A surface verification ............................................................................................................................31 6.1 Patc' .ro.erties...........................................................................................................................................31 6.2 Connectivity /nalysis ( 00 - Continuity.......................................................................................................31 6.3 Tangency /nalysis ( 01-Continuity............................................................................................................32 6.4 Curvature /nalysis.......................................................................................................................................33 6.% Reflection /nalysis.......................................................................................................................................33 6.6 -yna#ic 1ig'lig't /nalysis........................................................................................................................33 6. /!solute Curvature /nalysis........................................................................................................................34 6.8 ,ean Curvature /nalysis.............................................................................................................................34 6.$ ,a2i#u# and ,ini#u# Curvature /nalysis..............................................................................................34 6.10 0uassian surface /nalysis.........................................................................................................................34

Page 2 of 45

Subject: Class-A Surface Guidelines

") Curvature Anal#sis $ A case stu%#...................................................................................................................3 &) !ummar# of Class-A !urface !tan%ar%s.........................................................................................................3" 8.1 Classification of co#.onents and /..lica!le Class-/ standards ...............................................................3 8.2 Class-/ "tandard-*.......................................................................................................................................38 8.3 Class-/ "tandard-**.....................................................................................................................................38 8.4 Class-/ "tandard-***....................................................................................................................................3$ ') Manufacturin( Criteria)s $ Case stu%ies........................................................................................................4* $.1 Ti.s for #anufactura!ility of 'ood..............................................................................................................40 $.2 Ti.s for #anufactura!ility of fender............................................................................................................42 $.3 Ti.s for #anufactura!ility of Rear 3uarter .anel........................................................................................43

Page 3 of 45

Subject: Class-A Surface Guidelines

1)

Phases of Class-A surface creation

Figure 3.1-1

Page 4 of 45

Subject: Class-A Surface Guidelines

2)

Class-A surface Definition

Class-A surfaces and their require ents ha!e a close relationshi" #ith the aesthetics of a "roduct$ %he reflection of light "la&s a ajor role in surface a""earance$ 'f a surface does not "osses certain described characteristics( )isual a""earance of the "roduct #ill get affected$ Characteristics of Class-A surface can be classified into three ajor categories

Visual Characteristics
a* b* c* Aesthetic require ents +eflection( s oothness St&le features as intended b& ,esigner-St&list

Mathematical Requirements
d* e* f* g* . order continuit& /Positional Continuit& - G. Continuit&* 1 order continuit& /%angent Continuit& - G1 Continuit&* 2 order continuit& /Cur!ature Continuit&- G2 Continuit&* 3 order continuit& /Constant rate of change of cur!ature- G3 Continuit&*

Manufacturing requirements
h* i* j* 0* l* Panels should retain their sha"e - "ro"er stretching require ent should be ta0en care( St&led features should retain intended sha"es( 1eature lines li0e shoulder line or #aist line on bod& side "anel( feature lines on hood "anel should retain their "lace /s0idding*( 2ulge effect on flange lines should be a!oided( 3anufacturabilit& of sha"es /1or ing of sheet etal( 3oulded co "onents* etc$

Page 5 of 45

Subject: Class-A Surface Guidelines

,efects #hich do not qualif& for Class-A surface require ents Common isual !efects" #hich can $e attri$ute! to the $a! a%%earance of the surfaces * n* o* "* q* r* s* t* u* !* #* :* &* 9* aa* bb* 2ro0en reflection lines - #hich #ill affect the ho ogeneous loo0s of the car bod&( 4nintended highlights / 4nequal-5on "arallel* 5on-unifor transition highlights( iddle of s ooth surface - #hich a& result in !isual is atch of 4nderflush and 6!erflush conditions 7ocal dar0 s"ots in the colour( Cur!atures( 7ocal bright -unintended highlights( s"ots etc$ Connecti!it& "roble s li0e ga" and o!erla""ing along co %angenc& "roble bet#een t#o adjacent surfaces along co Cur!ature discontinuities bet#een surfaces( 2ad "ara eteri9ation( 2ad distribution of 'S6-"ara etric cur!es( %o"ological "roble s( %#isted "atches( 7ocal de"ressions and bu "s( %riangular "atches( etc$ on edge( on edge( Common Mathematical !efects foun! in surfaces

8ffect of trans"arent surfaces li0e #indshield( #indo# glasses and long lenses on surface

Common Manufacturing !efects foun! in surfaces For sheet metal %anels cc* dd* ee* ff* gg* hh* ii* jj* 00* ll* nn* oo* ""* 1lat surface ; inadequate lensings( Possibilit& of s0id Shar"( acute tri ar0s( lines and shut lines( is atch( 2ulge at flange lines( ,ra# de"th and corner radii

4nder flush and 6!er flush co-ordination( 7ocal de"ressions and bu "s etc$ Shrin0age 4ndercuts( * Seen "arting lines( 'nsufficient draft angle for gi!en te:tures( 'nadequate lensing( <ar"ing etc$ ar0s(

For Plastic com%onents 3olding direction(

Page = of 45

Subject: Class-A Surface Guidelines

3)

Mathematical Requirements
3.1 Positional Continuity OR 0 - Order continuity
Surface are said to be ha!ing Positional Continuit&( #hen the& "osses the follo#ing characteristics Adjacent faces-surfaces are sharing a co Ga" bet#een the edge on edge( ended tolerance li it along the co on

is less or equal to the reco

%he& are cur!ature continuous #ithin Refer images for more information

Surfaces are smooth

5ote: 1) Observe the smooth variation in reflection of light. 2) Observe the presence of sharp reflection line in the middle of the surface

&mage 3.1-1

Sharing Common edge

&mage 3.1-2

Page > of 45

Subject: Class-A Surface Guidelines

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

5ote: Angle between the Normals to the surface or curve on a point laying on the common edge is not within the set tolerance limit.

&mage 3.1-3

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

&mage 3.1-'

Mean Curvature Analysis result

&mage 3.1-(

Page ? of 45

Subject: Class-A Surface Guidelines

+efer i ages belo# for allo#able errors for acce"tance of surface for Positional continuit&

&mage 3.1-) !ndustr" Standard #$amples ,C@ )alue .$.2 G3 .$.25 16+, .$.2 28+%658 .$.1 %%7 .$.1

5ote: So e !alues gi!en here are based on the in"uts fro un-official source &mage 3.1-*

3.2 Tangent Continuity OR 1 - Order continuity

Surface are said to be ha!ing %angent Continuit&( #hen the& "osses the follo#ing characteristics$ Adjacent faces-surfaces are sharing a co Ga" bet#een the edge$ on edge$ ended !alue along the co on

is less or equal to the reco

Angle bet#een the nor als at an& co tolerance !alue$ %he& are cur!ature continuous #ithin$

on "oint on co

on edge is #ithin in the set

Refer $elo# images for more information

Page A of 45

Subject: Class-A Surface Guidelines

+urfaces are smooth 5ote: 1* 6bser!e the s ooth !ariation in reflection of light$ 2* 6bser!e the absence of shar" reflection line in the iddle of the surface in co "arison #ith 1igure for G. continuit&$

&mage 3.2-,

Sharing Common edge

&mage 3.2- 5ote: 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. &mage 3.2-1. Cur!ature Continuous #ithin Ga" bet#een the is #ithin the reco ended tolerance li it Share a co on edge

Page 1. of 45

Subject: Class-A Surface Guidelines

Dynamic reflection highlights Analysis Result

Note the abrupt deviation in highlights at Common edge.

&mage 3.2-11

Mean Curvature Analysis result

&mage 3.2-12 +efer i age belo# for allo#able errors for acce"tance of surface for %angent continuit&

!ndustr" Standard #$amples

,C@ )alue .$.5 G3 .$.5 16+, .$.> 28+%658 .$1 %%7 .$.5

5ote: So e !alues gi!en here are based on the in"uts fro un-official source

&mage 3.2-13

Page 11 of 45

Subject: Class-A Surface Guidelines

3.3 Curvature Continuity OR 2 - Order continuity

Surface are said to be ha!ing Cur!ature Continuit&( #hen the& "osses the follo#ing characteristics$ qq* rr* ss* tt* uu* Adjacent faces-surfaces are sharing a co Ga" bet#een the Angle bet#een the nor als at an& co tolerance !alue$ on edge$ ended !alue along the co on edge$ on "oint on co on edge is #ithin in the set is less or equal to the reco

)ariation in cur!ature !alue at t#o "oints on sa e cur!e on surface is #ithin s"ecified !alue$ %he& are cur!ature continuous #ithin$

Refer images for more information

Surfaces are smooth 5ote: 1* 6bser!e the s ooth !ariation in reflection of light$ 2) 6bser!e the unifor dis"ersion of light in the reflection 9one in the iddle of the surface in co "arison #ith 1igure for G1 continuit&.

&mage 3.3-1'

Sharing Common edge

&mage 3.3-1(

Page 12 of 45

Subject: Class-A Surface Guidelines

1* Cur!ature Continuous #ithin 2* Ga" bet#een the is #ithin in the tolerance li it 3* Share a co on edge 5ote: Angle between the normals to the surface or curve at a point laying on the common edge is within the set tolerance value.

&mage 3.3-1)

Dynamic reflection highlights Analysis Result 5ote the s ooth de!iation in highlights at Co edge on

&mage 3.3-1*

Mean Curvature Analysis result

&mage 3.3-1,

Page 13 of 45

Subject: Class-A Surface Guidelines

Refer image $elo# for allo#a$le errors for acce%tance of surface for cur ature continuit/

!ndustr" Standard #$amples

,C@ )alue .$..1 G3 .$..1 16+, .$..5 28+%658 .$.1 %%7 .$..1

5ote: So e !alues gi!en here are based on the in"uts fro un-official source

&mage 3.3-1Constant Rate of Change of Cur ature Continuit/ 0R 3 - 0r!er continuit/ Surface are said to be ha!ing Constant rate of change of cur!ature Continuit&( #hen the& "osses the follo#ing characteristics

Adjacent faces-surfaces are sharing a co Ga" bet#een the Angle bet#een the nor als at an& co !alue$

on edge( ended !alue along the co on edge on "oint on co on edge is #ithin in the set tolerance

is less or equal to the reco

)ariation in cur!ature !alue at t#o "oints on sa e cur!e on surface is #ithin s"ecified !alue$ ,istant bet#een t#o "oints on cur!es for #hich the change of cur!ature occurs has to be sa e for all "oint on the cur!es$

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 &one in the middle of the surface in comparison with 'igure for G2 continuit".

&mage 3.3-2.

Page 14 of 45

Subject: Class-A Surface Guidelines

Sharing Common edge

&mage 3.3-21

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

&mage 3.3-22

Dynamic reflection highlights Analysis Result

Note the smooth deviation in highlights at Common edge

&mage 3.3-23

Page 15 of 45

Subject: Class-A Surface Guidelines

Mean Curvature Analysis result

&mage 3.3-2'

Page 1= of 45

Subject: Class-A Surface Guidelines

')

Cur e Creation

Creation of a cur!e "la&s a !er& i "ortant role in the "rocess of Class-A surface creation$ %he qualit& of the cur!e dictates the qualit& of the surface$ Criteria for cur e creation

Cur!es should be of ini u required order as far as "ossible /"referred order-3 order is based on the soft#are being used* Cur!es should su""ort or facilitate the adjacent cur!e nature A!oid cur!e #ith inflection unless the& are a ust S"lit the cur!e as far as "ossible to a!oid unnecessar& tension Gi!e a close loo0 to cur!e descri"tors #hile creating cur!es

a:i u

4.1 Curve order

8!er& cur!e has a degree - a athe atical conce"t referring to the degree of the "ol&no ial that defines the cur!e$ %he degree is generall& one less than the nu ber of "oints in the cur!e descri"tor$ 1or this reason( &ou cannot ha!e a cur!e #ith lesser "oints than the degree of the cur!e$ A higher degree cur!e is stiffer( in the sense that &ou ha!e to o!e its "oles a long #a& to "roduce an& a""reciable change in the sha"e of the cur!e$ 7o#er degree cur!es are ore "liable( and tend to follo# their "oles uch ore closel&$ Bo#e!er( it is reco ended to use cur!es of degree 3$ Bigher degree cur!es are ore li0el& to contain undesirable oscillations$ Cou should use lo#er degree cur!es #hene!er "ossible /3( 4( and 5*$ 4se the default degree of three /3* unless &ou ha!e so e good reason for doing other#ise$ %he degree of a single seg ent cur!e is de"endent on the nu ber of its s"ecified "oints$ Refer images for more information

Curve of Degree 3, and Class 4 5ote: Cur!es of this t&"e are easier to handleD for an& change ade to the cur!e b& o!ing its "ole( the change in sha"e #ill be onotonic in nature across the cur!e$

&mage '.1-2(

Page 1> of 45

Subject: Class-A Surface Guidelines

Curve of Degree 5, and Class 6 5ote: Cur!es of this t&"e are not easier to handleD for an& change ade to the cur!e b& o!ing its "ole( the change in sha"e a& not be onotonic in nature across the cur!e because of high "ara eterisation of the cur!e$ Sha"e of the cur!e is e:actl& si ilar in sha"e and si9e to the cur!e sho#n in the i age$ &mage '.1-2)

Curve of Degree 6, and Class 5ote: Sha"e of the cur!e is e:actl& si ilar in sha"e and si9e to the cur!e sho#n in ' age 4$1 -25 and ' age 4$1 -2= on "age 5o$ 1= 6bser!e the bad "ara eterisation of the cur!e( #hich is not desirable for Class-A surface creation$

&mage '.1-2*

4.2 Case study for curve creation

<hile creating a cur!e fro distribution of the cur!e$ digitised "oints( it is essential to gi!e a close loo0 to the "ara eter

'n the gi!en e:a "le( e!en though cur!es are e:actl& si ilar in sha"e( si9e and "osition the& are not identical in their athe atical "ro"erties$ Cur e Degree *" Class , 5ote: 6bser!e the cur!e "ara eter distribution( #hich is erratic$ Cur!e is of !er& high degree and class( #hich is not reco ended$ 6bser!e the adulations in cur!ature !ariation as seen fro the cur!ature nor als$

&mage '.2-2,

Page 1? of 45

Subject: Class-A Surface Guidelines

Curve Degree 3, Class 4 5ote: S ooth !ariation in cur!e "ara eter distribution$ ,esired sha"e is achie!ed b& a cur!e of lo#er degree and class( #hich is highl& reco ended$ 6bser!e the cur!ature !ariation as seen fro the cur!ature nor als$ %he !ariation in this case is s ooth as co "ared to the earlier case$

&mage '.2-2-

4.3 Curve Redistribution

Curve of Degree ! and Class "# 5ote: 6bser!e highl& ha"ha9ard distribution of cur!e "ara eters$ Cur!e created b& soft#are tool fro data$ digiti9ed

&mage '.3-3.

Curve of Degree ! and Class "# 5ote: 6bser!e s ooth and onotonic !ariation in distribution of cur!e "ara eters Cur!e created b& using s oothing technique$ o"ti i9ation and

&mage '.3-31

Page 1A of 45

Subject: Class-A Surface Guidelines

Curvature analysis of the Curve

&mage '.3-32

4.4 Creation of Sy

etry Curves

1or cur!es( #hich are to be used in creating surfaces for "anels li0e Bood( <indshield( +oof( %run0 lid and 1ront and rear bu "ers( s"ecial care has to be ta0en #hile creating the cur!es and surfaces$ <hile creating s& 2* 3* 4* 5* =* etr& cur!es chec0 the follo#ing "ro"erties in the cur!e etr& should be EFeroG etr& should be E FeroG etr& should be E FeroG etr&$ Cur!ature continuit& !alue at the "lane of s& %angenc& continuit& at "lane of s& Positional continuit& at "lane of s& 't is reco 't is not reco

ended to ha!e cur!es of ,egree 3(5 and Class 4(= ended to ha!e a cur!e node at "lane of s&

Symmetry Curve 5ote: 6bser!e the absence of cur!e node at "lane of s& etr&( ost of the ti es this condition auto aticall& ensures G.( G1 and G2 continuit&$

Figure '.'-2

4.! "oundary curve creation

<hile creating end boundar& cur!e for "atches( chec0 for the follo#ing characteristics in the cur!es$ 2oth cur!es should be of

Sa e class and degree Si ilar nature in athe atical "ara eterisation$

Change in cur!e "ara eter distribution should be onotonic in nature$ 'n the absence of abo!e characteristics( chances of internal surface distortions are !er& high$

Page 2. of 45

Subject: Class-A Surface Guidelines

$nd %oundary curves 5ote: 6bser!e "ol&no ial distribution of the cur!es$

&mage '.(-33

$nd %oundary curves 5ote: 6bser!e the change in the "ol&no ial distribution of the cur!es and the change in the cur!e "osition due to this$

&mage '.(-3'

Page 21 of 45

Subject: Class-A Surface Guidelines

()

+urface Creation

As e:"lained in the earlier cha"ter( qualit& of the surface "la&s ajor role in aesthetics of the "roduct( it is !er& i "ortant #e ta0e a lot of care #hile creating a surface$ A"art fro basic require ents li0e "ositional continuit&( tangent continuit& and cur!ature continuit&( follo#ing criteriaHs has to be gi!en due consideration$

!.1 Criteria for surface creation Patch1+urface %arameterisation

Pol&no ial re"resentation of a surface is defined b& a net#or0 of lines and "oints( %hese control "oints or "oles are distributed o!er sections$

Patch1Face Plan
,i!ision or s"litting of "atches to create features in surfaces

&+0-cur e !istri$ution +urface o er-$uil!ing an! trimming of surface

Creation of e:tra surface be&ond the required area for co "onent design

Minimum !escri%ti e %rofiles for surface creation

4se ini u or surface$ required nu ber of end boundaries and internal su""ort "rofiles to define a "atch

+/mmetr/ criteria
Guidelines for creation of s& etric surfaces$

2ransition surface creation

Ioining of t#o ain surfaces #ith another surface$

+urface or face tension

Bigh concentration of "atch descri"tors in a local area of a "atch-face( because of cur!ature$ a:i u

+urface com%leteness
Co "letel& defined surface in all res"ects( b& athe atical definitions$

Fillets

Page 22 of 45

Subject: Class-A Surface Guidelines

!.2 Patc#$Surface Para eteri%ation

Patch or surface is said to be of good qualit& #hen it has the follo#ing characteristics a* b* c* d* Good distribution of "atch descri"tors or !ertices Patch should not "ossess an& 0in0s in the descri"tors "attern$ 3ini u 4nifor nu ber of descri"tors !ariation in descri"tor "attern

Refer &mages for more information

&ood 'atch(face descri'tors 5ote: 3ini u nu ber descri"tors$ of "atch

S ooth !ariation in light reflection on the sha"e$

&mage (.2-3(

)ad 'atch(*ace descri'tors 5ote : Bigh nu ber of "atch descri"tors$ Jin0 in one of the descri"tors$

&mage (.2-3)

Page 23 of 45

Subject: Class-A Surface Guidelines

Patch-1ace Plan ' "ortant as"ect of good surface creation is "atch "lan$ 't is i "ortant for the surface creator to "lan the "atch-face s"lit to achie!e good qualit& in surfaces$ Good "atch-face "lan goes a long #a& in hel"ing creation of good erging of ain surfaces( creation of features( ter ination of features( corners( transition surfaces( bends etc$ onl& e:"erience can hel" in deciding "atch-face "lan Refer &mages for more information

Shaded image of fender

&mage (.2-3*

+atch(*ace 'lan of fender

&mage (.2-3,

Page 24 of 45

Subject: Class-A Surface Guidelines

!.3 &SO-Para etric Curve distribution

,istribution of 'S6-cur!es is the "ri ar& indication of a good qualit& "atch$

)ad ,S-.curve distri%ution 5ote: ,istribution of 'S6-Para etric cur!es is not ho ogeneous 3a& ha!e local surface tension$ S ooth !ariation is not there$ Cur!es are bent and Cur!es are straight$

&mage (.3-3-

&ood ,S-.curve distri%ution 5ote: S ooth !ariation distribution in 'S6-Para etric cur!e

&mage (.3-'.

Difference %etween good and %ad ,S-.curve distri%ution of 'atch(face Note% (ath with )ad !SO*parametric curve distribution is shown in dotted lines. Observe the difference in shorter boundar" condition between two patches

&mage (.3-'1

Page 25 of 45

Subject: Class-A Surface Guidelines !.4 Patc#$'ace over building and tri !.! (ini u ing of Patc#$'ace

)escri*tive *rofile for surface creation

<hile creating a "atch( use ini u required nu ber of end boundaries and internal su""ort "rofiles to define a face or "atch$ %r& to create the ain "atches bigger than required area( 7ater tri the to a desired sha"e using tri ing "rofiles$ 5ote: e* f* 4se of high nu ber of "rofile to define the "atch a& result in bad qualit&$ Patch #ith ini u nu ber of constraints "osses characteristics li0e( good distribution of 'S6-"ara etric cur!es( 2etter "ara eteri9ation$ ore infor ation

+efer i age for

,efining "rofiles

+atch over %uilding

%ri

ing "rofiles

&mage (.(-'2

Page 2= of 45

Subject: Class-A Surface Guidelines

!.+ Sy

etry Criteria

<hile creating surface for Bood "anel( +oof( %run0 lid ( #indshield( +ear #indo# and tailgate( nor al "ractice is to create one side of the "anel( for other side surface is reflected$ <hile doing so( follo#ing criteria should be fulfilled at "lane of s& g* h* i* j*
S&

etr& 3405-Plane"67.)

Positional Continuit& %angenc& and cur!ature continuit& Cur!ature !ariation 5o directional !ariation
etr& Plane

Curvature of good symmetry 'atch 5ote: 'n this case Positional( %angenc&( and cur!ature continuities are fulfilled$ 6bser!e the length and sha"e !ariation of cur!ature nor al in the ar0ed area$

&mage (.)-'3 S& etr& Plane Curvature of %ad symmetry 'atch 5ote: 'n this case onl& Positional and %angenc& continuities are fulfilled$ 6bser!e the length and sha"e !ariation of cur!ature nor al in the ar0ed area$

&mage (.)-''

Page 2> of 45

Subject: Class-A Surface Guidelines

!., Transition Surface

Case stud& for the use of transition surface and its ad!antages

'ront fascia with transition surface

'ront fascia without transition surface Figure (.*-3

C + C

-%serve +wo main surfaces marked ,-. are /oined b" using transition surface marked ,C. +wo main corner surfaces marked ,C. are /oined b" using transition surface marked ,+.

-%serve Concept of using transition surfaces is not applied while creating the surface

Figure (.*-'
4nifor 'S6-cur!e distribution

'rregular

Page 2? of 45

Subject: Class-A Surface Guidelines

-%serve 0niform distribution of !SO*curves between main surface and transition surfaces. +his is the result of using a transition surface1 which gives more control over creating corner and /oining surfaces. -%serve !rregular distribution of !SO*curves in main surface.

Figure (.*-(

-%serve 0niform variation in !SO*curve shapes. S"nerg" in variation of gaps between !SO*curves distribution.

-%serve !rregular variation in !SO*curve shapes. !rregular variation of gaps between !SO*curves distribution.

Figure (.*-)

Page 2A of 45

Subject: Class-A Surface Guidelines

!.- Surface Co *leteness

Surface should be co "lete in all res"ects$ Chec0 for the follo#ing i "erfections li0e inco "lete filleting o"eration( untri corners( etc$ +efer i ages for further reference: ed "atches( undefined

-%serve untrimmed %ottom 'atch

4ntri

ed "atch Figure (.,-*

-%serve mar/ed area

'nco "lete 1illet

corner

and Figure (.,-,

Page 3. of 45

Subject: Class-A Surface Guidelines

!.. 'illets
<hile creating fillets for joining t#o surfaces-"atches( a!oid using circular - c&lindrical fillets$ %his 0ind of fillets( #ill not guarantee a good reflection effect because of the sudden change in cur!ature at the joining lines$ %o i "ro!e the aesthetic effects( it is suggested to use conical blending( #hich is a!ailable in soft#areHs li0e CA%'A and 84C7',-3$ 7i it the use of 1* 2* echanical blending to follo#ing areas 4nseen areas li0e corners( 1lange line blending( Ioggles on flanges etc$ 7ess i "ortant areas( li0e #here fillet radius required + is K 5$

+ +

Mechanical *illeting

&mage (.--'( Conical 1illeting

Conical *illeting

&mage (.--')

Page 31 of 45

Subject: Class-A Surface Guidelines

))

Class-A surface erification

+.1 Patc# *ro*erties

,S-.'arametric Curve distri%ution(+atch 'arameteri0ation

(ol"nomial representation of a surface1 defined b" a network of lines and points1 called control points or poles. +hese points are distributed over sections.

&mage ).1-'*

+.2 Connectivity /nalysis $ 00 - Continuity

&lo%al connectivity analysis %his ethod is used for finding out the ga"s in surface to"olog& connections$ Connecti!it& anal&sis result for hood surface is sho#n in follo#ing i ages$

&mage ).2-',

Page 32 of 45

Subject: Class-A Surface Guidelines

Green lines

&lo%al connectivity analysis <ire fra e odel of the hood surface( sho#n before sub itting for connecti!it& anal&sis 5ote: 6bser!e green lines in surface

&mage ).2-'&lo%al connectivity analysis Green lines +ed lines +esult of connecti!it& anal&sis Ga"s ore than .$.5 are sho#n in EredG colour Ga"s less than .$.5 and free edges are still sho#n in EgreenG colour$ Note: 1) Threshold value for connectivity analysis used in this case is 0.0 . "ethod of result display software dependent. is

!) &mage ).2-(.

+.3 Tangency /nalysis $ 01-Continuity

&lo%al 1angency Analysis %his ethod is used for finding angle bet#een t#o adjacent "atch along a co on edge$ Note: 1) !) #) Threshold value for connectivity analysis used in this case is 0.0 . Observe magenta coloured lines in surface. "ethod of dependent. result display is software

&mage ).3-(1

Page 33 of 45

Subject: Class-A Surface Guidelines +.4 Curvature /nalysis

Surface(+atch curvature analysis of a curve 7a&ing on a surface for unifor cur!ature 5ote: Cur!ature anal&sis of roof is sho#n$ !ariation in

&mage ).'-(2

+.! Reflection /nalysis

Dis'lay of the reflection lines created on a 'atch %y a line of light of infinite length

&mage ).(-(3

+.+ )yna ic 1ig#lig#t /nalysis

%his action is used to detect local fla#s on su""orting surfaces and to chec0 that surfaces are s ooth$ Bighlights are si ilar to reflection lines #ith the difference that highlights do not de"end on the userLs !ie# "oint$ 't is a si "lified reflection odel$ As #ith reflection lines( highlights agnif& discontinuities on a su""orting surface$%angent "lane discontinuit& bet#een t#o "atches in a surface is sho#n u" as discontinuous highlights$ ,iscontinuous highlight tangents sho#s cur!ature discontinuit& bet#een t#o "atches /shar" angle #here the contours join*$ Bighlights ha!e a lo#er order of continuit& than the surfaces the& are traced on$

Dis'lay of the Dynamic 2ighlights created on a roof surface

Page 34 of 45

Subject: Class-A Surface Guidelines

&mage ).)-('

+., /bsolute Curvature /nalysis

,t is used to detect the surface areas where the surface is locally almost flat, that is when the a%solute curvature is almost null3

&mage ).*-((

+.- (ean Curvature /nalysis

1he utmost values a''ear where the surface is the most war'ed3 Mean is largely used to detect irregularities on the surface3 A minimal surface is characteri0ed %y a null mean curvature3

&mage ).,-()

+.. (a2i u

and (ini u

Curvature /nalysis

1he geometric construction of main curvatures is the following4 let %e a 'lane containing the normal to the surface in a given 'oint3 1his 'lane cuts the surface along a curve that has a given curvature in this 'oint3 ,f this 'lane rotates around the normal, the curvatures of the curves of intersection with the surface will vary %etween two utmost values3 1hese two values are the main curvatures

&mage ).--(*

+.10 0uassian surface /nalysis

't describes the local sha"e of a surface in one "oint:

Page 35 of 45

Subject: Class-A Surface Guidelines

'f it is "ositi!e( the "oint is elli"tic( i$e$ the surface has locall& the sha"e of an elli"soid around the "oint$ 'f it is negati!e( the surface is h&"erbolic in this "oint( i$e$ the local sha"e is a horse saddle$ 'f it is null( the surface is "arabolic in this "oint( i$e$ one of the t#o ain cur!atures is null in this "oint$ Ps: %he cone and the c&linder are t#o surfaces #here all "oints are "arabolic$

5ocal de'ression on a roof surface Shown using &uassian surface analysis

&mage ).1.-(,

*)

Cur ature Anal/sis 8 A case stu!/

&ood roof surface Observe Smoothness of surface 0niform 2ispersion of light in reflection &one

Defective roof surface Observe Smoothness of surface 0niform 2ispersion of light in reflection &one &mage ).1.-(-

Page 3= of 45

Subject: Class-A Surface Guidelines

&ood roof surface Observe Smoothness of 2"namic highlights 0niform variation in d"namic highlight line shapes 0niform Gap between d"namic highlight lines Defective roof surface Observe Smoothness of 2"namic highlights 0niform variation in d"namic highlight line shapes Non*uniform Gap between d"namic highlight lines &mage ).1.-).

&ood roof surface -ean curvature anal"sis result

Defective roof surface -ean curvature anal"sis result &mage ).1.-)1

&ood roof surface Observe absence of local depression in Guassian curvature anal"sis result

Defective roof surface Observe presence of local depression in Guassian curvature anal"sis result &mage ).1.-)2

Page 3> of 45

Subject: Class-A Surface Guidelines

,)

+ummar/ of Class-A +urface +tan!ar!s

-.1 Classification of co *onents and /**licable Class-/ standards

S2$$1 M$1A5 +A6$5S

#$ternal (anels

!nternal (anel

#$ternal Seen

#$ternal 0nseen

!nternal Seen

!nternal 0nseen

Class 3 Standard !

Class 3 Standard !!

Class 3 Standard !!

Class 3 Standard !!!

Figure ,.1--

+lastic 1rims

#$ternal (anels

!nternal (anel

(ainted4+e$tured Seen

(ainted4+e$tured 0nseen

(ainted4+e$tured Seen

(ainted+e$tured 0nseen

Class 3 Standard !

Class 3 Standard !!

Class 3 Standard !!

Class 3 Standard !!!

Figure ,.1-1.

Page 3? of 45

Subject: Class-A Surface Guidelines

-.2 Class-/ Standard-&

A''lica%le *or 1) #$ternal seen Sheet metal panels 2) #$terior seen painted plastic trims Characteristics G5 6 (ositional Continuit" G1 6 +angenc" Continuit" G2 6 Curvature Continuit" G8 6 Constant rate of changes of curvature (atch descriptors !SO*curve distribution 'illets -anufacturabilit" criteria<s 2"namic highlights 2a$le ,-1 5.51 5.57 5.551 *** 9efer Section 7.2 9efer Section 7.: -echanical 'illets for ; 79 7 9efer Section = 9efer Section >.> Standards

-.3 Class-/ Standard-&&

A''lica%le *or 1) #$terior seen te$tured trims 2) !nterior seen te$tured trims 8) !nterior seen te$tured trims :) !nterior seen sheet panels plastic plastic plastic metal Characteristics G5 6 (ositional Continuit" G1 6 +angenc" Continuit" G2 6 Curvature Continuit" (atch descriptors !SO*curve distribution 'illets -anufacturabilit" criteria<s 2"namic highlights 2a$le ,-2 5.52 5.57 5.52 9efer Section 7.2 9efer Section 7.: -echanical 'illets for ; 79 7 9efer Section = 9efer Section >.> Standards

Page 3A of 45

Subject: Class-A Surface Guidelines

-.4 Class-/ Standard-&&&

A''lica%le *or 1) #$ternal unseen areas of Sheet metal panels #$ample% 3reas of )od" side panel hidden after door closer1 ?amp pockets1 -irror pockets on door frame1 #tc. 2) 0nseen painted and te$tured plastic trims Characteristics G5 6 (ositional Continuit" G1 6 +angenc" Continuit" G2 6 Curvature Continuit" (atch descriptors !SO*curve distribution 'illets -anufacturabilit" criteria<s 2"namic highlights 9ote: 3* 4* 5* %a0e care for not changing Est&ling intentG sha"es and features in all abo!e cases$ Seen eans - areas #hich are co ing in lines of direct !isual angle of a "erson standing ne:t to the car( and sitting inside the car$ 4nseen eans - areas #hich are not co ing in lines of direct !isual angle of a "erson standing ne:t to the car( and sitting inside the car$ 5.52 5.1 5.57 9efer Section 7.2 9efer Section 7.: -echanical 'illets for ; :9 7 9efer Section = 9efer Section >.> Standards

=*
>* ?* A* 1.*

; 'n case of fillet !alues ta0e care for

,ecide the odel$ a:i u

ini u

e:terior and interior "rojection regulations$ ,igitised data for each

allo#ed de!iation for Class-A surface creation fro St&ling de"art ent in case of de!iation fro

%a0e the a""ro!al fro 8:a "le: 3ini u

digiti9ed data$

6bser!e for regulator& require ents during the creation of Class-A surfaces$ e:ternal and internal "rojection regulations$ At the stage of design !erification( changes done on st&led surface #ith res"ect to the St&lingfree9e should be docu ented and agreed u"on$

Page 4. of 45

Subject: Class-A Surface Guidelines

-)

Manufacturing Criteria<s 8 Case stu!ies

6bjecti!e of this section is to lead st&list or "roduct engineers through the anufacturing "rocess for sheet etal$ Cases listed in this section of the docu ents are onl& for reference and 0no#ledge of the st&list and "roduct engineers$ %he cases e:"lained here are not to be considered as guidelines$ <hile designing the "anels for anufacturabilit&( "ro"er attention needs to be gi!en for follo#ing as"ects of sheet etal co "onents$ Panels should retain their sha"e after sta "ing "rocess( for the sa e "ro"er stretching require ent should be ta0en care( St&led features should retain intended sha"es( 1or e:a "le( 1eature lines li0e shoulder line or #aist line on bod& side "anel( 1eature lines on hood "anel should retain their "lace$ 2ulge effect on flange lines should be a!oided$ 'n the sa e #a&( #hile designing "lastic tri s( care should be ta0en care to a!oid #ar"ing of "anels at free ends( shrin0age effect on the areas #here internal ribs are "ro!ided for strength "ur"ose$

..1 Ti*s for

anufacturability of #ood

+ha!e! image of hoo! %anel &mage -.1-)3

Page 41 of 45

Subject: Class-A Surface Guidelines

Figure -.1-11

Page 42 of 45

Subject: Class-A Surface Guidelines

..2 Ti*s for

anufacturability of fender

+ha!e! &mage of Front fen!er =eft &mage -.2-)'

Page 43 of 45

Subject: Class-A Surface Guidelines

d 2

!n depth ,2. is not constant1 give constant offset depth ,d. to avoid bulge effect along flange line

!ndicator ?amp depression depth to be kept within 2*8 mm

759 6 -inimum 9adius to be kept

'eature line near wheel arch1 high risk of skidding1 if the panel is stretched to the ma$imum limit

!ncase of radical under sweeping at rear of wheel arch1 9educe the flange with to minimum possible

Figure -.2-12

..3 Ti*s for

anufacturability of Rear 3uarter *anel

2o not leave the feature line sharp for avoiding local stretching1 on the fillet. Complete them b" using conical filleting option with ma$imum possible ratio 'lange ?ine

@eep the feature line awa" from flange line b" minimum 27mm1 to avoid skidding effect.

-inimum angle suggested between the two surfaces creating this kind of feature is 25

Figure -.3-13

Page 44 of 45

Subject: Class-A Surface Guidelines

Figure -.3-1'

Page 45 of 45

Subject: Class-A Surface Guidelines

Figure -.3-1(