Design Guide lines for BIW panels

While designing matching radius of reinforcement should have bigger than the inner panel
radius to accommodate irregularities due to die wear.

Reinf.
Panel
Design Guide lines for BIW panels (Contd.)

Front Door
Design Guide lines for BIW panels (Contd.)

Any part ending against bending/stepped part minimum 3mm clearance should be followed
from the fillet end.
Design Guide lines for BIW panels (Contd.)

Rear Door
Design Guide lines for BIW panels (Contd.)
When two overlapping parts are welded we need to provide a joggle. The following dimensions need to be maintained:
X=5mm minimum, P= joggle depth equal to thickness of the part1.
Design Guide lines for BIW panels (Contd.)

Front Door

Rear Door
Design Guide lines for BIW panels (Contd.)
When two welding flanges are ending with same edge, one welding flange should have
1.7mm clearance from the other welding flange edge.

15-20.0 mm width for weld flange

When three welding flanges are ending with same edge follow the clearances as per
below image.

3
1.7
Design Guide lines for BIW panels (Contd.)

Front Door

Body side
 Design Guide lines for BIW panels (Contd.)
To ensure proper sealing on body side at B-pillar corner area it is necessary to reduce
flange length as per below image

L
R
L-2

R=minimum 45mm For moulded joints

L
Recommended 70mm R=minimum 35mm
Design Guide lines for BIW panels (Contd.)
On every part extremity of door seal flange surface give 10x3 chamfer or 5mm radius to
match with body side for easy assembly and to avoid injuries during manipulation.
Design Guide lines for BIW panels (Contd.)

Rear Door
Design Guide lines for BIW panels (Contd.)
For rectangular or square holes minimum 3mm radius must be given, 1mm radius or
less can potentially generate cracks.

4 CORNERS R (min.)= 3mm

R R

R R
Design Guide lines for BIW panels (Contd.)
Ensure for flanged holes (any shape) flange height should be minimum 3Tmm
(T=Thickness of the part)

Rear Door
Design Guide lines for BIW panels (Contd.)
Ensure that the dimensions shown in the image are maintained for pierced or
extruded (flanged) holes.
R= Bend radius
r= Radius of pierced hole
T= Thickness of the component

2r

2r
6r
Design Guide lines for BIW panels (Contd.)

Case-1: Ensure minimum 40mm overlapping length for assembly of two spot welds
Case-2: For one spot weld

Case - 1 Case - 2

25
Design Guide lines for BIW panels (Contd.)

Minimum flange width after fillet considered for spot welding is 12mm
In straight zones spot welding pitch should be 50mm for 5 mm diameter of spot

50

12
X
X
Rear Door
Design Guide lines for BIW panels (Contd.)

While designing reinforcement for inner panel other than welding surfaces it is
necessary to provide minimum 5mm clearance in between reinforcement and inner
panel.

B-Pillar
Design Guide lines for BIW panels (Contd.)

Rear Door
Design Guide lines for BIW panels (Contd.)

Maintain following rule for bending corner radius R.

R=3X
R= corner radius
X= step height

R
 Design Guide lines for BIW panels (Contd.)

Necessary to provide E-coat drain holes in lower areas (box sections) like closures and body
side sill.

Front Door

Elpo drain hole

Design Guide lines for BIW panels (Contd.)

Ensure following conditions for hemming.

7-12

Closures

7-12

7-12

Wheel arch
Design Guide lines for BIW panels (Contd.)

For mastic application minimum clearance kept in between inner and outer panel is
2mm.
Total depth considered for mastic sealant is 5mm.

Tail Gate
Design Guide lines for BIW panels (Contd.)

In outer panels relief is provided on flanges at bending before hemming

operation to prevent folding of material.

Hood
Design Guide lines for BIW panels (Contd.)

While designing inner panels (roof/ lift gate/door) at water proof area minimum flat
surface against seal must be 20mm. Package seal with a 3 to 5mm crush, in body position.

Lift Gate bottom

Design Guide lines for BIW panels (Contd.)

 In order to strengthen component against bending (deflection) stiffener/beads to be

provided along the length of the component to protrude in opposite direction to the
bending force applied.
 Minimum bending radius considered is 5T.
Stiffener/
bead

Bending
radius
Design Guide lines for BIW panels (Contd.)

Ensure mounting locations made stiffen by raising surface locally as shown.

Rear Door
 Design Guide lines for BIW panels (Contd.)

Following is the fixing method in hinge area and brackets with inner panels

Lift Gate top

Design Guide lines for BIW panels (Contd.)

Avoid deep draw depths by gradually reducing depth as a slope or steps of lesser depths.

Steps
Rear Door
Design Guide lines for BIW panels (Contd.)

Minimum draft angle for sheet metal part is 10degrees with respect to stamping direction.

Rear Door
Design Guide lines for BIW panels (Contd.)

 Component is design to its outer surface (class A) as it is visible surface.

 Outer panels are generally designed to thickness range of 0.8 to 1.0 mm to meet
performance of denting and hail storm requirement.
 Inner panels are generally designed to thickness range of 1.0 to 1.6 mm.
 Smooth & large fillet is provided between connecting sections to prevent failure due to
bending.
 Design has to meet performance while balancing Mass, Piece cost & tooling investment.