BIW Design

BIW Design Dos and Donts

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 Dos and Donts

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. IngressEgress 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
Form the panels
Presses
Dies
Checking
Fixtures

Body Shop
Assemble the
panels
Fixtures
Welding Guns
Checking
Fixtures
Metal
Finishing tools
Conveyers

Paint Shop

Trim Line

Painting Body

Body Trimming

Pre-treatment

I/P Fitment

Oven Baking

Seat Fitment

Finishing

Glasses

Painting

Trim

Oven Baking

Carpets

Inspection

Final Assy
Vehicle Rolldown
Power Train
Suspension
Steering
Fuel System
Brakes
Alignments

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

Door Inner Panel

Roof bow middle

Roof bow rear

Tail Gate panel

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