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Subject: Class-A Surface Guidelines: Page 1 of 45
Subject: Class-A Surface Guidelines: Page 1 of 45
Contents
1) Phases of Class-A surface creation....................................................................................................................3
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......................................................................................................................17
4.3 Curve Redistribution ...................................................................................................................................18
4.4 Creation of Symmetry Curves......................................................................................................................19
4.5 Boundary curve creation..............................................................................................................................19
5) Surface Creation...............................................................................................................................................21
5.1 Criteria for surface creation .......................................................................................................................21
5.2 Patch/Surface Parameterization..................................................................................................................22
5.3 ISO-Parametric Curve distribution.............................................................................................................24
5.4 Patch/Face over building and trimming of Patch/Face...............................................................................25
5.5 Minimum Descriptive profile for surface creation......................................................................................25
5.6 Symmetry Criteria........................................................................................................................................26
5.7 Transition Surface........................................................................................................................................27
5.8 Surface Completeness..................................................................................................................................29
5.9 Fillets...........................................................................................................................................................30
Figure 3.1-1
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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
Image 3.1-1
Image 3.1-2
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Image 3.1-3
Image 3.1-4
Image 3.1-5
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Refer images below for allowable errors for acceptance of surface for Positional continuity
Image 3.1-6
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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Image 3.2-8
Image 3.2-9
Image 3.2-10
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Image 3.2-11
Image 3.2-12
Refer image below for allowable errors for acceptance of surface for Tangent continuity
Image 3.2-13
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Image 3.3-14
Image 3.3-15
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Image 3.3-16
Image 3.3-17
Image 3.3-18
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Refer image below for allowable errors for acceptance of surface for curvature continuity
Image 3.3-19
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
Image 3.3-20
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Image 3.3-21
Image 3.3-22
Image 3.3-23
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Image 3.3-24
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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
Image 4.1-25
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Image 4.1-26
Image 4.1-27
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.
Image 4.2-28
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Image 4.2-29
4.3 Curve Redistribution
Image 4.3-30
Image 4.3-31
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Image 4.3-32
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) Curvature continuity value at the plane of symmetry should be “Zero”
3) Tangency continuity at plane of symmetry should be “ Zero”
4) Positional continuity at plane of symmetry should be “ Zero”
5) It is recommended to have curves of Degree 3,5 and Class 4,6
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 4.4-2
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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Image 4.5-33
Image 4.5-34
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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 criteria’s 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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Good patch/face
descriptors
Note:
Minimum number of patch
descriptors.
Smooth variation in light reflection
on the shape.
Image 5.2-35
Bad patch/Face
descriptors
Note :
High number of patch descriptors.
Kink in one of the descriptors.
Image 5.2-36
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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
Image 5.2-37
Image 5.2-38
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Image 5.3-39
Image 5.3-40
Image 5.3-41
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Defining profiles
Patch over
building
Trimming profiles
Image 5.5-42
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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 5.6-43
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 5.6-44
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Front fascia with transition surface Front fascia without transition surface
Figure 5.7-3
C M
M
Observe Observe
Two main surfaces marked “M” are joined Concept of using transition surfaces is not
by using transition surface marked “C” applied while creating the surface
Two main corner surfaces marked “C” are
joined by using transition surface marked
“T”
Figure 5.7-4
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Uniform Irregular
ISO-curve distribution
Observe Observe
Uniform distribution of ISO-curves Irregular distribution of ISO-curves in main
between main surface and transition surface.
surfaces.
This is the result of using a transition
surface, which gives more control over
creating corner and joining surfaces.
Figure 5.7-5
Observe Observe
Uniform variation in ISO-curve shapes. Irregular variation in ISO-curve shapes.
Synergy in variation of gaps between ISO- Irregular variation of gaps between ISO-
curves distribution. curves distribution.
Figure 5.7-6
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Untrimmed patch
Figure 5.8-7
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
software’s like CATIA and EUCLID-3.
Limit the use of mechanical blending to following areas
1) Unseen areas like corners, Flange line blending, Joggles on flanges etc.
2) Less important areas, like where fillet radius required R is < 5.
R
Mechanical Filleting
Image 5.9-45
Conical Filleting
Conical Filleting
Image 5.9-46
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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 6.1-47
6.2 Connectivity Analysis / G0 - Continuity
Image 6.2-48
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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 6.2-49
Image 6.2-50
6.3 Tangency Analysis / G1-Continuity
Image 6.3-51
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Image 6.4-52
6.5 Reflection Analysis
Image 6.5-53
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.
Image 6.6-54
6.7 Absolute Curvature Analysis
Image 6.7-55
6.8 Mean Curvature Analysis
Image 6.8-56
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 6.9-57
6.10 Guassian surface Analysis
It describes the local shape of a surface in one point:
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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.
Image 6.10-58
Image 6.10-59
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Image 6.10-60
Image 6.10-61
Image 6.10-62
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Figure 8.1-9
Plastic Trims
Figure 8.1-10
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Table 8-1
8.3 Class-A Standard-II
Applicable For Characteristics Standards
1) Exterior seen G0 – Positional Continuity 0.02
plastic textured
G1 – Tangency Continuity 0.05
trims
2) Interior seen G2 – Curvature Continuity 0.02
plastic textured Patch descriptors Refer Section 5.2
trims
3) Interior seen ISO-curve distribution Refer Section 5.4
plastic textured Fillets Mechanical Fillets for <
trims 5R *
4) Interior seen
sheet metal panels Manufacturability criteria’s Refer Section 9
Dynamic highlights Refer Section 6.6
Table 8-2
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Note:
3) Take care for not changing “styling intent” shapes and features in all above cases.
4) 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.
5) 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.
6) * In case of fillet values take care for minimum exterior and interior projection regulations.
7) Decide the maximum allowed deviation for Class-A surface creation from Digitised data for each
model.
8) Take the approval from Styling department in case of deviation from digitized data.
9) 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 Styling-
freeze should be documented and agreed upon.
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Image 9.1-63
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Figure 9.1-11
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d
D
50R – Minimum
Radius to be kept
Figure 9.2-12
9.3 Tips for manufacturability of Rear quarter panel
Keep the feature line away fromflange line by Do not leave the feature line sharp for avoiding
minimum25mm, to avoid skidding effect. local stretching, on the fillet. Complete themby
using conical filleting option with maximum
possible ratio
Flange Line
Figure 9.3-13
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Figure 9.3-14
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Figure 9.3-15