Guidelines Class A

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Ref No PP70-P07
Page 1 of 63
Subject: Class-A Surface Guidelines
ssue No 001 Re!ision 001
Contents
1)Phases of Class-A surface creation..................................................................................................................... 3
2)Class-A surface Definition................................................................................................................................... 4
3)Mathematical Requirements............................................................................................................................... 8
4)Positional Continuity OR 0 - Order continuity.................................................................................................8
5)Tangent Continuity OR 1 - Order continuity.................................................................................................. 12
6)Curvature Continuity OR 2 - Order continuity..............................................................................................16
7)Cure Creation................................................................................................................................................... 23
8)Curve order.....................................................................................................................................................2
!)Case study "or curve creation......................................................................................................................... 26
10)Curve Redistri#ution ....................................................................................................................................2$
11)Creation o" %y&&etry Curves....................................................................................................................... 28
12)'oundary curve creation.............................................................................................................................. 2!
13)!urface Creation.............................................................................................................................................. 31
14)Criteria "or sur"ace creation ........................................................................................................................1
15)Patc()%ur"ace Para&eteri*ation...................................................................................................................
16)Patc()+ace Plan........................................................................................................................................... 5
1$),%O-Para&etric Curve distri#ution.............................................................................................................. 6
18)Patc()+ace over #uilding and tri&&ing o" Patc()+ace............................................................................... 8
1!)-ini&u& .escri/tive /ro"ile "or sur"ace creation....................................................................................... 8
20)%y&&etry Criteria......................................................................................................................................... !
21)Transition %ur"ace........................................................................................................................................ 40
22)%ur"ace Co&/leteness................................................................................................................................... 42
2)+illets............................................................................................................................................................ 4
24)Class-A surface erification ........................................................................................................................... 44
Review and Release Controlled By
Section Head ERC Styling Studio
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Prepared By Surendranath C Copy o! ""#
All rig"ts reser!ed Co#$rig"t %003 TATA Technologies Limited
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25)Patc( /ro/erties............................................................................................................................................44
26)Connectivity 0nalysis ) 10 - Continuity....................................................................................................... 44
2$)Tangency 0nalysis ) 11-Continuity............................................................................................................. 46
28)Curvature 0nalysis....................................................................................................................................... 46
2!)Re"lection 0nalysis........................................................................................................................................4$
0).yna&ic 2ig(lig(t 0nalysis......................................................................................................................... 4$
1)0#solute Curvature 0nalysis........................................................................................................................ 48
2)-ean Curvature 0nalysis............................................................................................................................. 48
)-a3i&u& and -ini&u& Curvature 0nalysis............................................................................................... 4!
4)1uassian sur"ace 0nalysis............................................................................................................................ 4!
3")Curature Anal#sis $ A case stu%#................................................................................................................. "&
3')!ummar# of Class-A !urface !tan%ar%s........................................................................................................ "2
$)Classi"ication o" co&/onents and 0//lica#le Class-0 standards ............................................................... 52
8)Class-0 %tandard-,....................................................................................................................................... 54
!)Class-0 %tandard-,,...................................................................................................................................... 54
40)Class-0 %tandard-,,,.....................................................................................................................................55
41)Manufacturin( Criteria)s $ Case stu%ies....................................................................................................... "'
42)Ti/s "or &anu"actura#ility o" (ood............................................................................................................... 56
4)Ti/s "or &anu"actura#ility o" "ender.............................................................................................................58
44)Ti/s "or &anu"actura#ility o" Rear 4uarter /anel........................................................................................ 60
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1) Phases of Class-A surface creation
Figure 3.1-1
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2) Class-A surface Definition
Class-A surfaces and t"eir re-uire(ents "a!e a close relations"i# *it" t"e aest"etics of a #roduct.
/"e reflection of lig"t #la$s a (ajor role in surface a##earance. f a surface does not #osses certain
described c"aracteristics0 1isual a##earance of t"e #roduct *ill get affected.
C"aracteristics of Class-A surface can be classified into t"ree (ajor categories
Visual Characteristics
Aest"etic re-uire(ents
Reflection0 s(oot"ness
St$le features as intended b$ 'esigner2St$list
athematical !e"uirements
0 order continuit$ &Positional Continuit$ 2 G0 Continuit$+
1 order continuit$ &/angent Continuit$ 2 G1 Continuit$+
% order continuit$ &Cur!ature Continuit$2 G% Continuit$+
3 order continuit$ &Constant rate of c"ange of cur!ature2 G3 Continuit$+
anufacturing re"uirements
Panels s"ould retain t"eir s"a#e - #ro#er stretc"ing re-uire(ent s"ould be ta)en care0
St$led features s"ould retain intended s"a#es0
3eature lines li)e s"oulder line or *aist line on bod$ side #anel0 feature lines on "ood
#anel s"ould retain t"eir #lace &s)idding+0
4ulge effect on flange lines s"ould be a!oided0
5anufacturabilit$ of s"a#es &3or(ing of s"eet (etal0 5oulded co(#onents+ etc.
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Defects #hich do not "ualif$ for Class-A surface re"uirements
Common %isual defects& #hich can 'e attri'uted to the 'ad a((earance of the surfaces
4ro)en reflection lines - *"ic" *ill affect t"e "o(ogeneous loo)s of t"e car bod$0
7nintended "ig"lig"ts & 7ne-ual2Non #arallel+
Non-unifor( transition "ig"lig"ts0
7nderflus" and 8!erflus" conditions
9ocal dar) s#ots in t"e (iddle of s(oot" surface - *"ic" (a$ result in !isual (is(atc" of
colour0
:ffect of trans#arent surfaces li)e *inds"ield0 *indo* glasses and long lenses on surface
Cur!atures0
9ocal brig"t -unintended "ig"lig"ts0 s#ots etc.
Common athematical defects found in surfaces
Connecti!it$ #roble(s li)e ga# and o!erla##ing along co((on edge0
/angenc$ #roble( bet*een t*o adjacent surfaces along co((on edge0
Cur!ature discontinuities bet*een surfaces0
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4ad #ara(eteri;ation0
4ad distribution of S8-#ara(etric cur!es0
/o#ological #roble(s0
/*isted #atc"es0
9ocal de#ressions and bu(#s0
/riangular #atc"es0 etc.
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Common anufacturing defects found in surfaces
For sheet metal panels
3lat surface < inade-uate lensings0
Possibilit$ of s)id (ar)s0
4ulge at flange lines0
S"ar#0 acute tri( lines and s"ut lines0
'ra* de#t" and corner radii (is(atc"0
7nder flus" and 8!er flus" co-ordination0
9ocal de#ressions and bu(#s etc.
For Plastic components
S"rin)age (ar)s0
5olding direction0
7ndercuts0
Seen #arting lines0
nsufficient draft angle for gi!en te=tures0
nade-uate lensing0
>ar#ing etc.
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3) athematical !e"uirements
4) Positional Continuity OR 0 - Order continuity
Surface are said to be "a!ing Positional Continuit$0 *"en t"e$ #osses t"e follo*ing
c"aracteristics
Adjacent faces2surfaces are s"aring a co((on edge0
Ga# bet*een t"e( is less or e-ual to t"e reco((ended tolerance li(it along t"e co((on
edge
/"e$ are cur!ature continuous *it"in
!efer images for more information
Surfaces are smooth
Note:
#$ %&serve the smooth variation in reflection of light'
($ %&serve the presence of sharp reflection line in the
middle of the surface
)mage 3.1-1
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Sharing Common edge
)mage 3.1-2
Curvature Continuous within
Share a common edge
)ap &etween them along the edge is within
tolerance limit
Note:
Angle between the Normals to the surface or
curve on a point laying on the common edge
is not within the set tolerance limit.
)mage 3.1-3
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Dynamic reflection highlights Analysis Result
ote the &ro*en Highlights at Common edge
)mage 3.1-*
Mean Curvature Analysis result
)mage 3.1-+
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Refer i(ages belo* for allo*able errors for acce#tance of surface for Positional continuit$
)mage 3.1-,
+ndustry Standard E,amples
'CA G5 38R' 4:R/8N: //9
1alue 0.0% 0.0%6 0.0% 0.01 0.01
Note: So(e !alues gi!en "ere are based on t"e in#uts
fro( un-official source
)mage 3.1--
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5) Tangent Continuity OR 1 - Order continuity
Surface are said to be "a!ing /angent Continuit$0 *"en t"e$ #osses t"e follo*ing
c"aracteristics.
Adjacent faces2surfaces are s"aring a co((on edge.
Ga# bet*een t"e( is less or e-ual to t"e reco((ended !alue along t"e co((on
edge.
Angle bet*een t"e nor(als at an$ co((on #oint on co((on edge is *it"in in t"e set
tolerance !alue.
/"e$ are cur!ature continuous *it"in.
!efer 'elo# images for more information
.urfaces are smooth
Note:
1+ 8bser!e t"e s(oot" !ariation in reflection
of lig"t.
%+ 8bser!e t"e absence of s"ar# reflection
line in t"e (iddle of t"e surface in
co(#arison *it" 3igure for G0 continuit$.
)mage 3.2-/
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Sharing Common edge
)mage 3.2-0
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Cur!ature Continuous *it"in
Ga# bet*een t"e( is *it"in t"e
reco((ended tolerance li(it
S"are a co((on edge
Note:
Angle between the normals to the surface or
curve at a point laying on the common edge is
within in the set tolerance value..
Observe the sudden change in curvature value
between the normals to the surface or curve at a
point laying on the common edge.
)mage 3.2-11
ote the a&rupt deviation in highlights at
Common edge'
)mage 3.2-11
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)mage 3.2-12
Refer i(age belo* for allo*able errors for acce#tance of surface for /angent continuit$
'CA G5 38R' 4:R/8N: //9
1alue 0.06 0.06 0.07 0.1 0.06
)mage 3.2-13
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) Curvature Continuity OR ! - Order continuity
Surface are said to be "a!ing Cur!ature Continuit$0 *"en t"e$ #osses t"e follo*ing c"aracteristics.
Adjacent faces2surfaces are s"aring a co((on edge.
Ga# bet*een t"e( is less or e-ual to t"e reco((ended !alue along t"e co((on edge.
Angle bet*een t"e nor(als at an$ co((on #oint on co((on edge is *it"in in t"e set
tolerance !alue.
1ariation in cur!ature !alue at t*o #oints on sa(e cur!e on surface is *it"in s#ecified
!alue.
/"e$ are cur!ature continuous *it"in.
Surfaces are smooth
Note:
1+ 8bser!e t"e s(oot" !ariation in reflection
of lig"t.
($ 8bser!e t"e unifor( dis#ersion of lig"t in
t"e reflection ;one in t"e (iddle of t"e
surface in co(#arison *it" 3igure for G1
continuit$'
)mage 3.3-1*
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Sharing Common edge
)mage 3.3-1+
1+ Cur!ature Continuous *it"in
%+ Ga# bet*een t"e( is *it"in in t"e
tolerance li(it
3+ S"are a co((on edge
Note:
Angle between the normals to the surface or
curve at a point laying on the common edge
is within the set tolerance value.
)mage 3.3-1,
Note t"e s(oot" de!iation in "ig"lig"ts at Co((on
edge
)mage 3.3-1-
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)mage 3.3-1/
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!efer image 'elo# for allo#a'le errors for acce(tance of surface for cur%ature continuit$
'CA G5 38R' 4:R/8N: //9
1alue 0.001 0.001 0.006 0.01 0.001
)mage 3.3-10
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Constant !ate of Change of Cur%ature Continuit$ 2! 3 - 2rder continuit$
Surface are said to be "a!ing Constant rate of c"ange of cur!ature Continuit$0 *"en t"e$ #osses t"e
follo*ing c"aracteristics
Adjacent faces2surfaces are s"aring a co((on edge0
Ga# bet*een t"e( is less or e-ual to t"e reco((ended !alue along t"e co((on edge
Angle bet*een t"e nor(als at an$ co((on #oint on co((on edge is *it"in in t"e set tolerance
!alue.
1ariation in cur!ature !alue at t*o #oints on sa(e cur!e on surface is *it"in s#ecified !alue.
'istant bet*een t*o #oints on cur!es for *"ic" t"e c"ange of cur!ature occurs "as to be sa(e
for all #oint on t"e cur!es.
Surfaces are smooth
ote!
#$ %&serve the smooth variation in reflection of light'
($ %&serve the further improvement in uniform
dispersion of light in the reflection -one in the
middle of the surface in comparison with .igure for
)( continuity'
)mage 3.3-21
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Sharing Common edge
)mage 3.3-21
Curvature Continuous within
)ap &etween them is within the set tolerance
value
Share a common edge
ote!
Distance between points on curve on the surface For
which curvature changes is constant
)mage 3.3-22
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ote the smooth deviation in highlights at
Common edge
)mage 3.3-23
)mage 3.3-2*
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-) Cur%e Creation
Creation of a cur!e #la$s a !er$ i(#ortant role in t"e #rocess of Class-A surface creation. /"e -ualit$
of t"e cur!e dictates t"e -ualit$ of t"e surface.
Criteria for cur%e creation
Cur!es s"ould be of (ini(u( re-uired order as far as #ossible &#referred order-3 (a=i(u(
order is based on t"e soft*are being used+
Cur!es s"ould su##ort or facilitate t"e adjacent cur!e nature
A!oid cur!e *it" inflection unless t"e$ are a (ust
S#lit t"e cur!e as far as #ossible to a!oid unnecessar$ tension
Gi!e a close loo) to cur!e descri#tors *"ile creating cur!es
") Curve order
:!er$ cur!e "as a degree - a (at"e(atical conce#t referring to t"e degree of t"e #ol$no(ial t"at
defines t"e cur!e. /"e degree is generall$ one less t"an t"e nu(ber of #oints in t"e cur!e descri#tor.
3or t"is reason0 $ou cannot "a!e a cur!e *it" lesser #oints t"an t"e degree of t"e cur!e.
A "ig"er degree cur!e is stiffer0 in t"e sense t"at $ou "a!e to (o!e its #oles a long *a$ to #roduce an$
a##reciable c"ange in t"e s"a#e of t"e cur!e. 9o*er degree cur!es are (ore #liable0 and tend to
follo* t"eir #oles (uc" (ore closel$. Bo*e!er0 it is reco((ended to use cur!es of degree 3.
Big"er degree cur!es are (ore li)el$ to contain undesirable oscillations. Cou s"ould use lo*er degree
cur!es *"ene!er #ossible &30 ,0 and 6+. 7se t"e default degree of t"ree &3+ unless $ou "a!e so(e
good reason for doing ot"er*ise. /"e degree of a single seg(ent cur!e is de#endent on t"e nu(ber of
its s#ecified #oints.
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Curve of Degree 3, and Class 4
Note:
Cur!es of t"is t$#e are easier to "andleD for an$
c"ange (ade to t"e cur!e b$ (o!ing its #ole0 t"e
c"ange in s"a#e *ill be (onotonic in nature across
t"e cur!e.
)mage *.1-2+
Curve of Degree , and Class !
Note:
Cur!es of t"is t$#e are not easier to "andleD for an$
c"ange (ade to t"e cur!e b$ (o!ing its #ole0 t"e
c"ange in s"a#e (a$ not be (onotonic in nature
across t"e cur!e because of "ig" #ara(eterisation of
t"e cur!e.
S"a#e of t"e cur!e is e=actl$ si(ilar in s"a#e and
si;e to t"e cur!e s"o*n in t"e i(age.
)mage *.1-2,
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Curve of Degree !, and Class "
Note:
S"a#e of t"e cur!e is e=actl$ si(ilar in s"a#e
and si;e to t"e cur!e s"o*n in (age ,.1-%6 and
(age ,.1-%6 on #age No. %,
8bser!e t"e bad #ara(eterisation of t"e cur!e0
*"ic" is not desirable for Class-A surface
creation.
)mage *.1-2-
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#) Case study $or curve creation
>"ile creating a cur!e fro( digitised #oints0 it is essential to gi!e a close loo) to t"e #ara(eter
distribution of t"e cur!e.
n t"e gi!en e=a(#le0 e!en t"oug" cur!es are e=actl$ si(ilar in s"a#e0 si;e and #osition t"e$ are not
identical in t"eir (at"e(atical #ro#erties.
Cur%e Degree -& Class /
Note:
8bser!e t"e cur!e #ara(eter distribution0 *"ic"
is erratic.
Cur!e is of !er$ "ig" degree and class0 *"ic" is
not reco((ended.
8bser!e t"e adulations in cur!ature !ariation as
seen fro( t"e cur!ature nor(als.
)mage *.2-2/
Curve Degree 3, Class 4
Note:
S(oot" !ariation in cur!e #ara(eter distribution.
'esired s"a#e is ac"ie!ed b$ a cur!e of lo*er
degree and class0 *"ic" is "ig"l$ reco((ended.
8bser!e t"e cur!ature !ariation as seen fro( t"e
cur!ature nor(als. /"e !ariation in t"is case is
s(oot" as co(#ared to t"e earlier case.
)mage *.2-20
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10) Curve Redistri%ution
Curve of Degree # and Class $%
Note:
8bser!e "ig"l$ "a#"a;ard distribution of cur!e
#ara(eters.
Cur!e created b$ soft*are tool fro( digiti;ed
data.
)mage *.3-31
Curve of Degree # and Class $%
Note:
8bser!e s(oot" and (onotonic !ariation in
distribution of cur!e #ara(eters
Cur!e created b$ using o#ti(i;ation and
s(oot"ing tec"ni-ue.
)mage *.3-31
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Curvature analysis of the Curve
)mage *.3-32
11) Creation o$ &ymmetry Curves
3or cur!es0 *"ic" are to be used in creating surfaces for #anels li)e Bood0 >inds"ield0 Roof0
/run) lid and 3ront and rear bu(#ers0 s#ecial care "as to be ta)en *"ile creating t"e cur!es
and surfaces.
>"ile creating s$((etr$ cur!es c"ec) t"e follo*ing #ro#erties in t"e cur!e
1+ Cur!ature continuit$ !alue at t"e #lane of s$((etr$ s"ould be EFeroG
%+ /angenc$ continuit$ at #lane of s$((etr$ s"ould be E FeroG
3+ Positional continuit$ at #lane of s$((etr$ s"ould be E FeroG
,+ t is reco((ended to "a!e cur!es of 'egree 306 and Class ,06
6+ t is not reco((ended to "a!e a cur!e node at #lane of s$((etr$.
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Symmetry Curve
Note:
8bser!e t"e absence of cur!e node at #lane of
s$((etr$0 (ost of t"e ti(es t"is condition
auto(aticall$ ensures G00 G1 and G% continuit$.
Figure *.*-2
1!) 'oundary curve creation
>"ile creating end boundar$ cur!e for #atc"es0 c"ec) for t"e follo*ing c"aracteristics in t"e cur!es.
4ot" cur!es s"ould be of
Sa(e class and degree
Si(ilar nature in (at"e(atical #ara(eterisation.
C"ange in cur!e #ara(eter distribution s"ould be (onotonic in nature. n t"e absence of abo!e
c"aracteristics0 c"ances of internal surface distortions are !er$ "ig".
&nd 'oundary curves
Note:
8bser!e #ol$no(ial distribution of t"e cur!es.
)mage *.+-33
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&nd 'oundary curves
Note:
8bser!e t"e c"ange in t"e #ol$no(ial
distribution of t"e cur!es and t"e c"ange in t"e
cur!e #osition due to t"is.
)mage *.+-3*
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13) .urface Creation
As e=#lained in t"e earlier c"a#ter0 -ualit$ of t"e surface #la$s (ajor role in aest"etics of t"e #roduct0 it
is !er$ i(#ortant *e ta)e a lot of care *"ile creating a surface. A#art fro( basic re-uire(ents li)e
#ositional continuit$0 tangent continuit$ and cur!ature continuit$0 follo*ing criteriaHs "as to be gi!en due
consideration.
14) Criteria $or sur$ace creation
Patch3.urface (arameterisation
Pol$no(ial re#resentation of a surface is defined b$ a net*or) of lines and #oints0 /"ese control
#oints or #oles are distributed o!er sections.
Patch3Face Plan
'i!ision or s#litting of #atc"es to create features in surfaces
).2-cur%e distri'ution
.urface o%er-'uilding and trimming of surface
Creation of e=tra surface be$ond t"e re-uired area for co(#onent design
inimum descri(ti%e (rofiles for surface creation
7se (ini(u( re-uired nu(ber of end boundaries and internal su##ort #rofiles to define a #atc"
or surface.
.$mmetr$ criteria
Guidelines for creation of s$((etric surfaces.
Transition surface creation
Ioining of t*o (ain surfaces *it" anot"er surface.
.urface or face tension
Big" concentration of #atc" descri#tors in a local area of a #atc"2face0 because of (a=i(u(
cur!ature.
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.urface com(leteness
Co(#letel$ defined surface in all res#ects0 b$ (at"e(atical definitions.
Fillets
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15) Patch(&ur$ace Parameteri)ation
Patc" or surface is said to be of good -ualit$ *"en it "as t"e follo*ing c"aracteristics
Good distribution of #atc" descri#tors or !ertices
Patc" s"ould not #ossess an$ )in)s in t"e descri#tors #attern.
5ini(u( nu(ber of descri#tors
7nifor( !ariation in descri#tor #attern
!efer )mages for more information
(ood )atch*face descri)tors
Note:
5ini(u( nu(ber of #atc"
descri#tors.
S(oot" !ariation in lig"t reflection
on t"e s"a#e.
)mage +.2-3+
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+ad )atch*,ace descri)tors
Note :
Big" nu(ber of #atc" descri#tors.
Jin) in one of t"e descri#tors.
)mage +.2-3,
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Page 36 of 63
1) Patch(Face Plan
(#ortant as#ect of good surface creation is #atc" #lan. t is i(#ortant for t"e surface creator
to #lan t"e #atc"2face s#lit to ac"ie!e good -ualit$ in surfaces. Good #atc"2face #lan goes a long
*a$ in "el#ing creation of good (erging of (ain surfaces0 creation of features0 ter(ination of
features0 corners0 transition surfaces0 bends etc. onl$ e=#erience can "el# in deciding #atc"2face
#lan
!efer )mages for more information
Shaded image of fender
)mage +.3-3-
-atch*,ace )lan of fender
)mage +.3-3/
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 36 of 63
1*) +&O-Parametric Curve distri%ution
'istribution of S8-cur!es is t"e #ri(ar$ indication of a good -ualit$ #atc".
+ad .SO/curve distri'ution
Note:
'istribution of S8-Para(etric cur!es is not
"o(ogeneous
5a$ "a!e local surface tension.
S(oot" !ariation is not t"ere. Cur!es are bent
and Cur!es are straig"t.
)mage +.*-30
(ood .SO/curve distri'ution
Note:
S(oot" !ariation in S8-Para(etric cur!e
distribution
)mage +.*-*1
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Effective Date

TATA MOTORS
Ref No PP70-P07
Page 37 of 63
Difference 'etween good and 'ad .SO/curve
distri'ution of )atch*face
ote!
Path with Bad +S%/parametric curve distri&ution is shown in
dotted lines'
%&serve the difference in shorter &oundary condition
&etween two patches
)mage +.*-*1
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Effective Date

TATA MOTORS
Ref No PP70-P07
Page 3? of 63
1") Patch(Face over %uilding and trimming o$ Patch(Face
1#) ,inimum -escriptive pro$ile $or sur$ace creation
>"ile creating a #atc"0 use (ini(u( re-uired nu(ber of end boundaries and internal su##ort
#rofiles to define a face or #atc". /r$ to create t"e (ain #atc"es bigger t"an re-uired area0 9ater
tri( t"e( to a desired s"a#e using tri((ing #rofiles.
Note:
7se of "ig" nu(ber of #rofile to define t"e #atc" (a$ result in bad -ualit$.
Patc" *it" (ini(u( nu(ber of constraints #osses c"aracteristics li)e0 good distribution of
S8-#ara(etric cur!es0 4etter #ara(eteri;ation.
Refer i(age for (ore infor(ation
-atch over
'uilding
)mage +.,-*2
Approved By
Effective Date
'efining #rofiles
/ri((ing #rofiles

TATA MOTORS
Ref No PP70-P07
Page 3@ of 63
!0) &ymmetry Criteria
>"ile creating surface for Bood #anel0 Roof0 /run) lid 0 *inds"ield0 Rear *indo* and tailgate0
nor(al #ractice is to create one side of t"e #anel0 for ot"er side surface is reflected.
>"ile doing so0 follo*ing criteria s"ould be fulfilled at #lane of s$((etr$ 4526-Plane&781)
Positional Continuit$
/angenc$ and cur!ature continuit$
Cur!ature !ariation
No directional !ariation
Curvature of good symmetry )atch
Note:
n t"is case Positional0 /angenc$0 and
cur!ature continuities are fulfilled.
8bser!e t"e lengt" and s"a#e !ariation of
cur!ature nor(al in t"e (ar)ed area.
)mage +.--*3
Curvature of 'ad symmetry )atch
Note:
n t"is case onl$ Positional and /angenc$
continuities are fulfilled.
8bser!e t"e lengt" and s"a#e !ariation of
cur!ature nor(al in t"e (ar)ed area.
)mage +.--**
Approved By
Effective Date
S$((etr$ Plane
S$((etr$ Plane

TATA MOTORS
Ref No PP70-P07
Page ,0 of 63
!1) Transition &ur$ace
Case stud$ for t"e use of transition surface and its ad!antages
.ront fascia with transition surface .ront fascia without transition surface
Figure +./-3
O'serve
0wo main surfaces mar*ed 123 are 4oined &y using
transition surface mar*ed 1C3
0wo main corner surfaces mar*ed 1C3 are 4oined &y using
transition surface mar*ed 103
O'serve
Concept of using transition surfaces is not applied while
creating the surface
Figure +./-*
Approved By
Effective Date
2
C
2
0
C

TATA MOTORS
Ref No PP70-P07
Page ,1 of 63
O'serve
5niform distri&ution of +S%/curves &etween main surface
and transition surfaces'
0his is the result of using a transition surface6 which gives
more control over creating corner and 4oining surfaces'
O'serve
+rregular distri&ution of +S%/curves in main surface'
Figure +./-+
O'serve
5niform variation in +S%/curve shapes'
Synergy in variation of gaps &etween +S%/curves
distri&ution'
O'serve
+rregular variation in +S%/curve shapes'
+rregular variation of gaps &etween +S%/curves distri&ution'
Figure +./-,
Approved By
Effective Date
7nifor(
S8-cur!e distribution
rregular

TATA MOTORS
Ref No PP70-P07
Page ,% of 63
!!) &ur$ace Completeness
Surface s"ould be co(#lete in all res#ects.
C"ec) for t"e follo*ing i(#erfections li)e inco(#lete filleting o#eration0 untri((ed #atc"es0 undefined
corners0 etc.
Refer i(ages for furt"er reference:
O'serve untrimmed 'ottom )atch
Figure +.0--
O'serve mar0ed area
Figure +.0-/
Approved By
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7ntri((ed #atc"
nco(#lete corner and 3illet

TATA MOTORS
Ref No PP70-P07
Page ,3 of 63
!.) Fillets
>"ile creating fillets for joining t*o surfaces2#atc"es0 a!oid using circular 2 c$lindrical fillets.
/"is )ind of fillets0 *ill not guarantee a good reflection effect because of t"e sudden c"ange in
cur!ature at t"e joining lines.
/o i(#ro!e t"e aest"etic effects0 it is suggested to use conical blending0 *"ic" is a!ailable in
soft*areHs li)e CA/A and :7C9'-3.
9i(it t"e use of (ec"anical blending to follo*ing areas
1+ 7nseen areas li)e corners0 3lange line blending0 Ioggles on flanges etc.
%+ 9ess i(#ortant areas0 li)e *"ere fillet radius re-uired R is K 6.
Mechanical ,illeting
)mage +.11-*+
Conical ,illeting
Approved By
Effective Date
R
Conical 3illeting
R

TATA MOTORS
Ref No PP70-P07
Page ,, of 63
)mage +.11-*,
2*) Class-A surface %erification
!5) Patch properties
.SO/)arametric Curve distri'ution*-atch
)arameteri1ation
Polynomial representation of a
surface6 defined &y a networ* of
lines and points6 called control
points or poles' 0hese points are
distri&uted over sections'
)mage ,.1-*-
!) Connectivity /nalysis ( 00 - Continuity
(lo'al connectivity analysis
/"is (et"od is used for finding out t"e ga#s in
surface to#olog$ connections.
Connecti!it$ anal$sis result for "ood surface is
s"o*n in follo*ing i(ages.
)mage ,.2-*/
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page ,6 of 63
>ire fra(e (odel of t"e "ood surface0 s"o*n
before sub(itting for connecti!it$ anal$sis
Note:
8bser!e green lines in surface
)mage ,.2-*0
Result of connecti!it$ anal$sis
Ga#s (ore t"an 0.06 are s"o*n in
EredG colour
Ga#s less t"an 0.06 and free edges
are still s"o*n in EgreenG colour.
Note:
1) Threshold value for connectivity
analysis used in this case is
0.0.
!) "ethod of result display is
software dependent.
)mage ,.2-+1
Approved By
Effective Date
Green lines
Green lines
Red lines

TATA MOTORS
Ref No PP70-P07
Page ,6 of 63
!*) Tangency /nalysis ( 01-Continuity
(lo'al Tangency Analysis
/"is (et"od is used for finding angle bet*een
t*o adjacent #atc" along a co((on edge.
Note:
1) Threshold value for connectivity analysis
used in this case is 0.0.
!) Observe magenta coloured lines in surface.
#) "ethod of result display is software
dependent.
)mage ,.3-+1
!") Curvature /nalysis
Surface*-atch curvature analysis of a curve
9a$ing on a surface for unifor( !ariation in
cur!ature
Note:
Cur!ature anal$sis of roof is s"o*n.
)mage ,.*-+2
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page ,7 of 63
!#) Re$lection /nalysis
Dis)lay of the reflection lines created on a )atch 'y
a line of light of infinite length
)mage ,.+-+3
.0) -ynamic 1ighlight /nalysis
/"is action is used to detect local fla*s on su##orting surfaces and to c"ec) t"at surfaces are s(oot".
Big"lig"ts are si(ilar to reflection lines *it" t"e difference t"at "ig"lig"ts do not de#end on t"e userLs
!ie* #oint. t is a si(#lified reflection (odel. As *it" reflection lines0 "ig"lig"ts (agnif$ discontinuities
on a su##orting surface./angent #lane discontinuit$ bet*een t*o #atc"es in a surface is s"o*n u# as
discontinuous "ig"lig"ts. 'iscontinuous "ig"lig"t tangents s"o*s cur!ature discontinuit$ bet*een t*o
#atc"es &s"ar# angle *"ere t"e contours join+. Big"lig"ts "a!e a lo*er order of continuit$ t"an t"e
surfaces t"e$ are traced on.
Dis)lay of the Dynamic 2ighlights created on a roof
surface
)mage ,.,-+*
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page ,? of 63
.1) /%solute Curvature /nalysis
.t is used to detect the surface areas where the
surface is locally almost flat, that is when the
a'solute curvature is almost null3
)mage ,.--++
.!) ,ean Curvature /nalysis
The utmost values a))ear where the surface is the
most war)ed3 Mean is largely used to detect
irregularities on the surface3 A minimal surface is
characteri1ed 'y a null mean
curvature3
)mage ,./-+,
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page ,@ of 63
..) ,a2imum and ,inimum Curvature /nalysis
The geometric construction of main curvatures is
the following4 let 'e a )lane containing the normal
to the surface in a given )oint3 This )lane cuts the
surface along a curve that has
a given curvature in this )oint3 .f this )lane rotates
around the normal, the curvatures of the curves of
intersection with the surface will vary 'etween two
utmost values3 These two values are the main
curvatures
)mage ,.0-+-
.4) 0uassian sur$ace /nalysis
t describes t"e local s"a#e of a surface in one #oint:
f it is #ositi!e0 t"e #oint is elli#tic0 i.e. t"e surface "as locall$ t"e s"a#e of an elli#soid around t"e #oint.
f it is negati!e0 t"e surface is "$#erbolic in t"is #oint0 i.e. t"e local s"a#e is a "orse saddle. f it is null0
t"e surface is #arabolic in t"is #oint0 i.e. one of t"e t*o (ain cur!atures is null in t"is #oint.
Ps: /"e cone and t"e c$linder are t*o surfaces *"ere all #oints are #arabolic.
5ocal de)ression on a roof surface Shown using
(uassian surface analysis
)mage ,.11-+/
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 60 of 63
3+) Cur%ature Anal$sis 9 A case stud$
(ood roof surface
%&serve
Smoothness of surface
5niform Dispersion of light in reflection -one
Defective roof surface
%&serve
Smoothness of surface
5niform Dispersion of light in reflection -one
)mage ,.11-+0
(ood roof surface
%&serve
Smoothness of Dynamic highlights
5niform variation in dynamic highlight line shapes
5niform )ap &etween dynamic highlight lines
%&serve
Smoothness of Dynamic highlights
5niform variation in dynamic highlight line shapes
on/uniform )ap &etween dynamic highlight lines
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 61 of 63
)mage ,.11-,1
(ood roof surface
2ean curvature analysis result
2ean curvature analysis result
)mage ,.11-,1
(ood roof surface
%&serve a&sence of local depression in
)uassian curvature analysis result
%&serve presence of local depression in
)uassian curvature analysis result
)mage ,.11-,2
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 6% of 63
3,) .ummar$ of Class-A .urface .tandards
.*) Classi$ication o$ components and /pplica%le Class-/ standards
S2&&T M&TA5 -A6&5S
E,ternal Panels +nternal Panel
E,ternal Seen E,ternal 5nseen +nternal Seen +nternal 5nseen
Class A Standard + Class A Standard ++ Class A Standard ++ Class A Standard +++
S2&&T M&TA5 -A6&5S
E,ternal Seen E,ternal 5nseen +nternal Seen +nternal 5nseen
Figure /.1-0
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 63 of 63
-lastic Trims
Painted70e,tured Seen Painted70e,tured 5nseen Painted70e,tured Seen Painted0e,tured 5nseen
-lastic Trims
Painted70e,tured Seen Painted70e,tured 5nseen Painted70e,tured Seen Painted0e,tured 5nseen
Figure /.1-11
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 6, of 63
.") Class-/ &tandard-+
A))lica'le ,or Characteristics Standards
#$ E,ternal seen Sheet metal
panels
($ E,terior seen
painted plastic trims
)" Positional Continuity "'"#
)# 0angency Continuity "'"8
)( Curvature Continuity "'""#
)9 Constant rate of changes of curvature ///
Patch descriptors Refer Section 8'(
+S%/curve distri&ution Refer Section 8':
.illets
2echanical .illets for ; 8R 7
2anufactura&ility criteria<s Refer Section =
Dynamic highlights Refer Section >'>
Ta'le /-1
.#) Class-/ &tandard-++
#$ E,terior seen plastic
te,tured trims
($ +nterior seen plastic
te,tured trims
9$ +nterior seen plastic
te,tured trims
:$ +nterior seen sheet metal
panels
)" Positional Continuity "'"(
)# 0angency Continuity "'"8
)( Curvature Continuity "'"(
.illets
2echanical .illets for ; 8R 7
Ta'le /-2
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 66 of 63
40) Class-/ &tandard-+++
#$ E,ternal unseen areas of
Sheet metal panels
E,ample! Areas of Body
side panel hidden after
door closer6 ?amp
poc*ets6 2irror poc*ets on
door frame6 Etc'
($ 5nseen painted and
te,tured plastic
trims
)" Positional Continuity "'"(
)# 0angency Continuity "'#
)( Curvature Continuity "'"8
.illets
2echanical .illets for ; :R 7
:ote;
1+ /a)e care for not c"anging Est$ling intentG s"a#es and features in all abo!e cases.
%+ Seen (eans - areas *"ic" are co(ing in lines of direct !isual angle of a #erson standing ne=t
to t"e car0 and sitting inside t"e car.
3+ 7nseen (eans - areas *"ic" are not co(ing in lines of direct !isual angle of a #erson standing
ne=t to t"e car0 and sitting inside t"e car.
,+ < n case of fillet !alues ta)e care for (ini(u( e=terior and interior #rojection regulations.
6+ 'ecide t"e (a=i(u( allo*ed de!iation for Class-A surface creation fro( 'igitised data for eac"
(odel.
6+ /a)e t"e a##ro!al fro( St$ling de#art(ent in case of de!iation fro( digiti;ed data.
7+ 8bser!e for regulator$ re-uire(ents during t"e creation of Class-A surfaces.
:=a(#le: 5ini(u( e=ternal and internal #rojection regulations.
?+ At t"e stage of design !erification0 c"anges done on st$led surface *it" res#ect to t"e St$ling-
free;e s"ould be docu(ented and agreed u#on.
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 66 of 63
*1) anufacturing Criteria=s 9 Case studies
8bjecti!e of t"is section is to lead st$list or #roduct engineers t"roug" t"e (anufacturing #rocess for
s"eet (etal. Cases listed in t"is section of t"e docu(ents are onl$ for reference and )no*ledge of t"e
st$list and #roduct engineers. /"e cases e=#lained "ere are not to be considered as guidelines.
>"ile designing t"e #anels for (anufacturabilit$0 #ro#er attention needs to be gi!en for follo*ing
as#ects of s"eet (etal co(#onents.
Panels s"ould retain t"eir s"a#e after sta(#ing #rocess0 for t"e sa(e #ro#er stretc"ing re-uire(ent
s"ould be ta)en care0 St$led features s"ould retain intended s"a#es0 3or e=a(#le0 3eature lines li)e
s"oulder line or *aist line on bod$ side #anel0 3eature lines on "ood #anel s"ould retain t"eir #lace.
4ulge effect on flange lines s"ould be a!oided.
n t"e sa(e *a$0 *"ile designing #lastic tri(s0 care s"ould be ta)en care to a!oid *ar#ing of #anels at
free ends0 s"rin)age effect on t"e areas *"ere internal ribs are #ro!ided for strengt" #ur#ose.
4!) Tips $or manu$actura%ility o$ hood
.haded image of hood (anel
)mage 0.1-,3
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 67 of 63
Figure 0.1-11
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 6? of 63
4.) Tips $or manu$actura%ility o$ $ender
.haded )mage of Front fender Left
)mage 0.2-,*
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 6@ of 63
+n depth 1D3 is not constant6 give constant offset
depth 1d3 to avoid &ulge effect along flange line
D
d
+ndicator ?amp depression depth to &e *ept
within (/9 mm
8"R 2inimum
Radius to &e *ept
.eature line near wheel arch6 high ris* of s*idding6
if the panel is stretched to the ma,imum limit
+ncase of radical under sweeping at rear of wheel
arch6 Reduce the flange with to minimum possi&le
+n depth 1D3 is not constant6 give constant offset
depth 1d3 to avoid &ulge effect along flange line
D
d
+ndicator ?amp depression depth to &e *ept
within (/9 mm
8"R 2inimum
Radius to &e *ept
.eature line near wheel arch6 high ris* of s*idding6
if the panel is stretched to the ma,imum limit
+ncase of radical under sweeping at rear of wheel
arch6 Reduce the flange with to minimum possi&le
Figure 0.2-12
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 60 of 63
44) Tips $or manu$actura%ility o$ Rear 3uarter panel
@eep the feature line away from flange line &y
minimum (8mm6 to avoid s*idding effect'
Do not leave the feature line sharp for avoiding
local stretching6 on the fillet' Complete them &y
using conical filleting option with ma,imum
possi&le ratio
.lange ?ine
2inimum angle suggested &etween the
two surfaces creating this *ind of feature is ("
@eep the feature line away from flange line &y

minimum (8mm6 to avoid s*idding effect'
Do not leave the feature line sharp for avoiding
local stretching6 on the fillet' Complete them &y
using conical filleting option with ma,imum
possi&le ratio
.lange ?ine
2inimum angle suggested &etween the
two surfaces creating this *ind of feature is ("
Figure 0.3-13
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Effective Date

TATA MOTORS
Ref No PP70-P07
Page 61 of 63
Figure 0.3-1*
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Effective Date

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Ref No PP70-P07
Page 6% of 63
Approved By
Effective Date

TATA MOTORS
Ref No PP70-P07
Page 63 of 63
Figure 0.3-1+
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Effective Date

Guidelines Class A

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@eep the feature line away from flange line &y

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