12128128, 9:57 AM = SKILL@LYNC fIW.Closure-Hood design BIW-Closure-Hood design DESIGN Project Detail ¥ BIW Closure - HOOD DESIGN ‘Objective: To design « Hood outer panel, inner panel and the necessary reinforc by the given Master section and design parameters. nts Theory: Hoot is a main component of front portion of a car. tis an opening body panel that covers the engine in front engine vehicle. It consist of an outer panel and inner panel. The inner panel provides the strength while the outer panel functions as the metal cover. It is an ‘access panel to the engine compartment to enable maintenance of power train, drive bolts, battery, fluid levels and lamp units. /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 sa12728128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Material Consideratior Hoods are typically made of the same material as the rest of the bodywork. This may include steel, aluminum, fiberglass, or carbon fiber. However, some aftermarket companies produce replacements for steel hoods in fiberglass or carbon fiber to make the vehicle lighter. Before we dive into the design, let us understand the rules and regulation standards for designing the hood. A perfect hood design means it should have a great impact distribution angled outside the car. In Japan and Europe, regulations have come into effect that places a limit on the severity of pedestrian head injury when struck by a motor vehicle. Ths is leading to more advancec hood designs, as evidenced by multicore hood inner panel designs. European Enhanced Vehicle-Safety Committee (EEVC), European New Car Assessment Program (euro NCAP) Design considerations: The human comfort factor for automobile design is first consideration. It is a method to safeguard and protect space for the human user and necessary components that make up the vehicle being designed, All safety regulations are ensured during this process. Ergonomical consideration consist of Hood clearance, Hood Opening angle and location © support rod or gas stay. Hood opening angle is different for different regions or countries. It is decided by the average height of the human in that particular count /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 2i2412028128, 9:57 AM SKILL@LYNC fIW.Closure-Hood design ‘There are two types of hood stay, support rod and Gas stay which holds the position of hood at desired angle. 1) Support rod Itis a simple metalic rod, tis not usually made linear to increase rigidity of rod but the length from line connecting support rod retaining point with retaing point on body side to maximum bending point should be less than 35mm to ensure the strength of support rod. It should have sufficient clearance with other engine components to avoid rattling noise. Gourmets are provided to keep the support rod in rest condition, hitpsseyne.comistudentproectshood-design-week-2-1211 saa12028128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Support rod Advantages of support rod are as follows * They are economical + Light in weight. Disadvantages of support rod are as follows + When striking with the automotive body panel to leave scars which are very likely to cause rust. * The metal rod is often too hot to be gripped by hands immidiately after the vehicle has been stopped. 2) Gas stay: Itis a device used for supporting the engine hood of a vehicle in its open postion by means of an actuator which is activated by gas. In case of gas stay only intial force is required to open the hood then it automatically open at desired angle with the extension of pneumatic piston in cylinder of gas stay assembly. Advantages of Gas stay are as follows * No human effort is required * Easy to operate Disadvantages of Gas stay are as follows * They are heavy in weight compared to support rod. hitpsseyne.comistudentproectshood-design-week-2-1211 4i2412028128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Safety requirement: ‘The most important safety requirement is regarding the frontal collision. It should withstand in high collision forces as well as it should divert the forces in outward direction so intensity of collision forces would be reduced to cabin side of car. hitpsseyne.comistudentproectshood-design-week-2-1211 512412028128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC collision with @ vohielo in urban traffic. The height, weight and age of the pedestrian all play a role in the kinematics of the event ‘and in his ability to survive. Most fatalities for the younger population are related to brain damage caused by head impact on the bonnet. For older people additional risks include rupture of arteries in the lower limbs and pelvis from bumper and bonnet leading edgesimpact frequency and seriousness of injury has been studied for many years, resulting in rating systems and improved design. Evaluation of pedestrian safety for a bonnet must be carried out in the context ofits surrounding elements like Vehicle styling, size (wrap around distance “WAD") and under bonnet clearance to other elements (considered as hard points). Local bonnet stiffness is influenced by mounting point stiffness such as hinges, bump stops and latches. This is better understood by superimposing the kinematies of a dummy onto the test conditions. \Wrap Around Distance (WAD) : itis the geometrically traced distance from the contact point with the Ground Reference Plane, vertically below the front face of the bumper, to an} point on the vehicle front structure. Side Reference line :- The geometric trace of the highest points of contact between a straight edge, held parallel to the lateral vertical plane of the vehicle and inclined 45 deg. traversed down the side of the front structure, and the side of the front structure. Child Head Impact Zone :~ 1000 WAD to 1500 WAD Adult Head Impact Zone :~ 1500 WAD to 2100 WAD Adult head form test d Child head form test a Upper leg form test - LA Leg form test ih > hitpsseyne.comistudentproectshood-design-week-2-1211 612412728128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC 77 SE REFERENCE LINES WRAP AROUND LINES 210mm — Nn IMPACT AREA nee Pe Blo casio 1500mm _ Peet IMPACT AREA | Ih, 6 2p | 1250mm A roles 100mm \A Besides functioning as an engine compartment cover, the hood of modern vehicles can also help manage the impact energy of a pedestrian’s head in a vehicle-pedestrian Impact. However, a hood's ability to absorb impact energy may be impeded by the proximity of the hood to components packaged inside the engine compartment, ie, by its underhood clearance. For example, for a given hood design, the hood's ability to absorb impact energy through deformation can be significantly reduced when the hood and engine block are in close proximity. Therefore, a large underhood clearance would be preferred for pedestrian protection.The predicted level of protection offered by the vehicle is verifiedby EURO-NCAP. Master section is a predefined sketch which will be adaptable for different situations. Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 7812728128, 9:57 AM fIW.Closure-Hood design SKILL@LYNC HOOD OUTER PANEL /—HOOD INNER PANEL | | Four main parts of Hood assembly are as follows + Outer Panel * Inner Panel * latch and striker system + Hinge system Hood Thickness Information * Outer Panel Thickness = 0.75mm. + Inner Panel Thickness = 0.76mm + Reinforcement Thickness = LSmm Outer Panel: We get the outer panel skin surface from style department with proper aesthetic look, gap etc. The shape of the Outer panel is made aerodynamic in order to minimize the air effect. ‘Shape of Outer panel is reffered as a base to design a inner panel Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 812412028128, 9:57 AM SKILL@LYNC BIW.Closure-Hood design InnerPanel: Hood Inner panel is main functional part in hood design. It gives structural support and strength to the outer panel of Hood. The outer and inner panels of the Hood are typically attached together using a hemming operation at the edges. hitpsseyne.comistudentproectshood-design-week-2-1211 siz12728128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC is system is the attachment of hood assembly and vehicle body. The hood latch system must be able to catch the striker of the hood upon closing and instantaneously, as well as ‘autornatically, lock. Once in the locked state, it must remain locked and only unlock upon the operator's control Hinge system : ‘The hinges are used to guide and hold the hood when open & close. Hinge assembly consists of two parts one is connected to the hood inner panel and second is connected te the vehicle body. Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 012412728128, 9:57 AM SKILL@LYNC BIW-Closure-Hood design Reinforcements Reinforcement are provided mainly in hinge and latch region. When hinge and latch ‘assemblies are attached to inner panel, strength of that area reduces locally so we add some additional material to increase the strength of the area locally. Thickness of reinforcement material is provided according to the design requirements. n this project, 5mm thickness has been given to both latch and hinge reinforcement. Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 a812028128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Lateh Trajectory: Circle Is drawn from the hinge axis center so we can finalize the position of latch striker. For proper mating, the tip of the striker should be tangential to the latch trajectory. the positior of latch striker follows the path of this circle, hitpsseyne.comistudentproectshood-design-week-2-1211 aie12028128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Emboss definitions: Embosses are provided to increose the strength of inner panel Shope of embosses also determines the direction of collision force cistribution. the shape of the embosses should be designed in such a way that, the collision forces should be directed towards outward side ofthe car (towards hinge side). Mastic data Mastic sealants used between the outer and inner panel. mastic sealants are the rubber like elasic compound which connects the outer and inner panels of car hood at specified points. Mastic sealants are used in the region between the inner and outer panel because ‘other joining process like welding or riveting are not good for car asthetic design. It also niipsifoktyne.comistudentproectsthood-design-week-2-1211 1312412028128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Draft Analysis: inner Panel niipsifoktyne.comistudentproectsthood-design-week-2-1211 aiza12728128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC SPLRAA TSIAN Manufacturing Aspects ‘The most important design consideration of any component is manufacturing aspect. In sheet metal, the component is manufactured by press tool dies. The Press tool is stamping which includes cutting operations like shearing, piercing etc. and forming operations like bending, Deep drawing, hemming etc. The main focus of manufacturing aspect is to manufacture hood assembly with minimum operation sequence and process time. Deep drawing: The manufacturing of deep, cuplike products from thin sheet metal is known as deep drawing. The process involves a punch with a round comer and a die with a large radius. The punch-die clearance is slightly larger than the thickness of the sheet metal to be deep drawn, {As the load applied through the punch, the sheet metal is forced to flow radially and sink into the die cavity to form a cup. The process is best suitable for complex shaped problem The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. A flat sheet metal blank is formed into a hollow body ‘open on one side or a hollow body is formed into a hollow body with a smaller cross- section Deep drawing creates a seamiess effect on metal, allowing for the creation of a smooth, curved edge. Deep drawn metal parts are created using a single metal blank, not a repeated course of metal blanks as is typically the case with traditional metal stamping, Deep drawing is one of the most widely used processes in sheet metal forming, Apart from its use in many other sectors, itis applied in the automotive industry for the manufacturing of car body parts. When drawing complex car body parts in practice, there is usually a combination of stretc! /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 1512412728128, 9:57 AM BIW-Closure-Hood design SKILL@LYNC Punch _ t Bt) Binder = = 1 Blank i jercing is a shearing process in which raw metal is pierced with a machining tool, resultin: in the creation of a circular or other shaped hole. Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 612412728128, 9:57 AM SKILL@LYNC BIW-Closure-Hood design Hemming: Hemming is a sheet metal forming process in which sheets are joined by bending it usualh to 180°. Automotive body panels and automotive parts. This assembly method is widely used in the final stages of production of automobile hoods doors, or other closures for aesthetic purposes. Itis a metalworking process that involves rolling the edge of sheet metal over and onto itself, essentially creating an area of two layers. During this process, the edge of sheet metal is folded over. The two newly formed layers then lie flush with each other. ‘The typical three-step bending process of the hemming operation comprising of the flanging, pre-hemming, and final hemming process. (@) (b) () (Outer Panel Flanging Radius(R,) Inner Part — Roll hemming: Roll hemming Is carried out incrementally with a hemming roller. An industrial robot guides the hemming roller and forms the flange. Rell hemming operation can also be divided into several pre-hemming and final hamming process steps. Roll hemming is very flexible to Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 sie12728123, 9:58 AM SKILL@LYNC BIW-Closure-Hood design EC Se roller inner part outer part 0.75 mm 0.75 mm @ CLEARANCE FOR HEM GLUL ‘Abend relief is nothing more than two small incisions cut into a piece of sheet metal to free the metal between the two. It separates the material you want to be able to fold from the rest of the part. You only need it when there is material on either side of a bend. Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 18124fIW.Closure-Hood design SKILL@LYNC Final assembly:12728128, 9:58 AM BIW-Closure-Hood design SKILL@LYNC the design and assembly of Hood. Leave a comment ‘Thanks for choosing to leave a comment, Please keep in ri comments are moderated as per our comment polley, and your email will nt be ivacy reasons. Please leave a personal & meaningful Please login to add a comment Other comments... No comments yet! 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The lens serve ‘mould after manufacturing the interior. a protective barrier against any det [23 Mar 2023 03:54 Pm ist (5) 23 Mor 2023 1209 Pm Ist cama /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 2012412728123, 9:58 AM BIW-Closure-Hood design SKILL@LYNC SKILL©LYNC Skill-Lyne offers industry relevant advanced engineering courses for engineering students by partnering with industry experts. 2 Our Company News & Events Blog Careers Grievance Redressal Skill-Lync Reviews Terms Privacy Policy Epowerx Learning Technologies Pvt Ltd BAID Hi-Tech Park 1298, 2nd & 3rd Floor, Valmiki Nagar, East Coast Road, Thiruvanmiyur, Chennai - 600041. info@skill-lyne.com MTgrievance@skill-lyne.com Top Individual Courses Computational Combustion Using Python and Cantera Introduetion to Physical Modeling using simscape Introduction to Structural Analysis using ANSYS Workbench Introduction to Structural Analysis using ANSYS Workbench Book Free Demo hntps:skl-yne.comvstudent-projetsihood-design-week-2-1211 2812128123, 9:58 AM BIW-Closure-Hood design SKILL@LYNC Post Graduate Program in Electric Vehicle Design & Development Skill-Lyne Plus Executive Program in Electric Vehicle Embedded Software Executive Program in Electric Vehicle Design Executive Program in Cybersecurity Trending Blogs Octave Code for Creating GIF Animation Files: A Step-by-Step Tutorial How To Use CAD/CAM Software To Improve Mechanical Designs Ethical Considerations in the usage of VR/AR in Medical Technology Clinical applications of Anatomy and Physiology in Medical Technology The Role of Anatomy and Physiology in Medical Technology Support © 2023 skill-Lync Inc. All Rights Reserved. Book Free Demo /ntps:skl-yne.comvstudent-projetshhood.design-week-2-1211 22812728128, 9:58 AM BIW-Closure-Hood design hitpsseyne.comistudentproectshood-design-week-2-1211 2312412028128, 9:58 AM BIW-Closure-Hood design hitpsseyne.comistudentproectshood-design-week-2-1211 24i2a