BIW Design

BIW Design Do’s and Don’ts

• 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 Do’s and Don’ts

• 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. Ingress-
Egress 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.
 Panel Design Guidelines
 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
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 Body Shop Paint Shop Trim Line Final Assy

Form the panels Assemble the Painting Body Body Trimming Vehicle Roll-
panels down
 Presses  Pre-treatment  I/P Fitment
 Fixtures  Power Train
 Dies  Oven Baking  Seat Fitment
 Welding Guns  Suspension
 Checking  Finishing  Glasses
Fixtures  Checking  Steering
 Painting  Trim
Fixtures
 Fuel System
 Oven Baking  Carpets
 Metal Finishing
 Brakes
tools  Inspection
 Alignments
 Conveyers
 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

Tail Gate panel

Door Inner Panel Roof bow middle Roof bow rear

Panel A pillar
Inner Sill Rear Inner

Hinge
Reinforcement

Rear Long Member

Shot gun panel

Bonnet Inner Rear Floor Panel

Cowl Panel

Hinge reinforcement
Floor Panel B pillar inner Body Side Panel
Thank You