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How Renault Uses

Numerical Control for
Car Body Design and Tooling

Pierre E. Bézier
Regie Nationale des Usines Renault

Automotive Engineering Congress

Detroit, Mich. 680010
January 8-12,1968
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Car Body Design and Tooling
FOR A LONG TIME, Renault has been interested in the pos-
sibilities offered by numerical control. First we dealt with
the " point to point" machining method applied to proto-
types, tooling (fixtures, multiheads, machine tool elements,
etc.) and crankshaft balancing. More recently, we have d e -
cided to use numerical control (NC) to design car bodies
and machine stamping tools.
In most existing processes described in the literature
(1-10)*, it seems that the use of NC starts only at the m o -
ment a model is "accepted" ; its shape is then considered
as "perfect" and no detectable alteration is to be brought
to it. On the contrary, we endeavor to use NC as early as
possible. Then the stylists and designers can use it to define
curves and surfaces without any need for a mathematician
to work out their conceptions.
REQUIRED CONDITIONS
Such a system must have the following features:
1. Materialize immediately, with a 0.005 in. precision,
a 3D curve (or its projections) determinated by numerical
data.
2. Be likely to represent a large variety of curves with-
out any need for the operator to have particular mathemati-
cal knowledge.
*Numbers in parentheses designate References at end of
paper.
Drawing and 3D milling machines are supplied with a
small computer acting as function generator. " Style" can
immediately loft curves and mill the shape of surfaces they
have conceived with good precision.
680010
How Renault Uses
Numerical Control for
Pierre E. Bézier
Régie Nationale des Usines Renault
3. Perform automatically, and almost immediately, con-
ventional operations of descriptive geometry.
4. Require a small amount of calculation to work out
data defining an entire surface or a group of surfaces. This
is to reduce computation delay and cost.
There is no need to point out the technical and economi-
cal position of European industry. It requires that such sys-
tem should be simple, of moderate price, and easily main-
tained.
DESCRIPTION OF SYSTEM
PRINCIPLE - A drawing or a milling machine is connected
to a very simple computer that elaborates the coordinates of
the points on the curve to be drawn. These points are close
enough so that interpolation be linear. Apart from that, this
computer works out the necessary calculation for interpola-
tion and control of motors. It controls simultaneously several
machines without any need for extra high-speed computa-
tion possibilties.
CURVE DEFINITION - The type of equation which seems
to be the most adequate for our needs is as follows:
Assuming that is a vector having for origin that of the
referential, and for extremity a point P, we can express it
with the relation:
ABSTRACT
Using this new method has led Renault to alter its way
of designing and tooling car bodies. The technique and
these alterations are described in this paper.
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For body design purposes, it seems sufficient to give "n"
a value between 3 and 5. Functions "f" respectively, have
the values 0 and 1 at the same time as .parameter ; so,
when varies from 0 to 1, point P runs a curve the ends of
which are the points, respectively, defined by:
According to purpose, we can give functions "f" very
diverse shapes, but we thought one of the simplest is given
in the following expression:
Among the interesting features of these functions, we
note:
1. They are symetric with respect to 8 and (1-8); that is
to say, we obtain the same curve in tracing one way or the
other along the polygon constituted with vectors a? placed
end to end in their index order.
2. The curve obtained is tangent in its ends to the first
and to the last vector different from zero.
3. The shape of the curve is related only to that of the
polygon constituted by vectors and is independant from
the referential; its projections are the curves connected to
the projections of the vector polygon. It is then sufficient
to apply the classic operations (translation and rotation)
of descriptive geometry to make the curve undergo the
same transformations.
These problems are easily solved with matrices.
The computer memory contains a number of "f" func-
tions values corresponding to the values of 0 graded between
0 and 1. When the operator has chosen the projections of
vectors the computer performs, for each value of 8, the
operations represented by Eq. 1 to calculate the coordinates
of point P corresponding to the value of the parameter.
Up to now, we only made vary by 0.01 increments,
but it would be easy to reduce this value for accuracy pur-
poses.
The curves shown on Figs. 1-3 were obtained, respec-
tively, with 3, 4, and 5 functions. We have drawn the vec-
tors corresponding to each of them. These vectors can be
intuitively chosen and, after working in successive attempts,
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one obtains the requested curve. If its shape is too complex,
it is subdivided into segments and each is treated separately.
If, on the contrary, we wish to make the curve pass through
a given number of points, an algebraic solution gives the
value of vectors dependent of the passing points coordinates
and tangents slopes imposed.
SURFACE DEFINITION
families, each being characterized by its own parameter.
Any relation between two parameters, as long as they re-
main within 0 and 1, represents a curve drawn on the sur-
face.
It is not indispensable that both curve families should
be defined with polygons formed with an equal number of
vectors, neither with identical functions.

As a polygon of vectors defines a 3D curve, a mesh of

vectors is adequate to define a surface segment (Fig. 4).
The polygon apexes defining each stringer are located on
curves defined by their own polygon (Fig. 5). Examples are
shown in Figs. 6-9. There are two families of conjugated
stringers on such surfaces; each curve meets every curve
belonging to the other family (Fig. 10).
Consequently, one point located on the surface is defined
as an intersection of two stringers belonging to two different
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BLENDING SURFACE SEGMENTS - In spite of the variety Other curves, such as surface intersections, are determinated
of curves this system can draw, it is not generally possible by the computing center. In this case, the coordinates of
to represent a complex 3D curve unless it is divided into each point are registered on a punched tape.
segments, each being of a simple enough shape to be de- The machine is, of course, supplied with a zero shift,
termined by one single polygon. To insure adequate connex- a "mirror image" switch, and various scales; any coordinate
ion between two curve segments, the condition is that the can be assigned to any axis, according to the wanted projec-
last side of the polygon must be colinear with the first side tion. The carrier bears a pencil, a stylus or a sight to pick
of the next one. up data.
The whole surface to be generated being divided by a MILLING MACHINE - This machine receives instructions
mesh of curves, blending adjacent surface segments imposes by means of a punched tape (Fig. 12). In a way similar to
a few simple rules. Whatever is the look of the border line, the drawing machine, it has a zero shift, mirror image, and
the operator chooses the shape of the ruled surface which a choice of scales; the tool tangential speed is controlled
contains the common normal to the surfaces along their from the control cabinet.
border. The milling machine we use has been designed for work-
Moreover, it is easy to alter the shape of a surface ele- ing on soft materials such as plaster, plastic, wood, compreg,
ment without changing any blending condition, that is to etc. It is equipped with a pointed tool, so that tool radius
say, without altering the adjacent surfaces. compensation is unnecessary.
However, in case of need, we can compute the orienta-
CONTROL MEANS tion of the normal to the surface in each point, since it
is located at the intersection of two stringers, the tangent
DRAWING MACHINE - The operator supplies the m a -
chine (Fig. 11) with -data of apexes of a character polygon
by means of dials or the printer keyboard. The printer also
types the information the operator wants from the computer.
The machine can also be used to loft the curves defined
previously or projections obtained by descriptive operations.
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of which is known. The work of the computer would be machine to produce the whole surface. This machine maxi-
increased. Consequently, the number of machines it can mum feed is 3/4 in./sec, so it takes only a few hours to
simultaneously control should be reduced, or it should be produce several solutions for the same problem.
supplied with adequate means for higher performance. FULL-SCALE MODEL (CLAY-MODEL) - While carrying
out these investigations, we prepare expanded polyurethane
PRACTICAL USE blocks covered with a layer of plastic. After machining,
they are assembled on a light frame to build the full-scale
Our experience is still rather limited, but we can already model. The model is lacquered, fitted with windshields,
draw a few conclusions and say how different phases of car panes, tires, headlights, etc., to make it look like a real car.
body design and tooling will be carried out when we take Any alteration decided upon as to the shape during the
full advantage of the possibilities offered by the numerical presentation session is immediately translated into the co-
control system we have chosen. ordinates of character polyhedrons. Thus, we can rapidly
SMALL SCALE MODEL - As in the past, stylists will con- produce several aspects of a "clay model" until the final
tinue to materialize their conceptions with the sketches decision is reached on one of them.
and drawings which result in small scale clay models. It is FINAL DRAWINGS - When this decision is known the de-
from these models that the final "style" is chosen. signer prepares the drawings with all their details: inside
GENERAL LAYOUT DRAWING - Starting with the elected panels, seals, brackets, mechanical parts settings, etc. One
small scale model, the designer elaborates the curve mesh must admit that designing outside panels is not the most
that will divide the whole surface into segments (Figs. 13-16). difficult part of the task. Production engineering specialists
This choice accounts for part geometry and manufacturing are constantly kept informed and their comments are sought.
possibilities. The coordinates of a few points belonging to MASTER - When a car is numerically defined in its en-
each curve are picked up from the small scale model and tirety, the need for a master may become debatable. For
put down on the drawing machine. Then we define the char- the time being, we feel it can still help to partly define
acteristic polygon for each curve segment. As drafting speed auxiliary surfaces of tools, and in any case, it is very useful
is about 2-1/2 sfpm, we can rapidly try a few solutions. for their final fitting. Exceptions aside, the character lines
When we are satisfied with the shape of the curves, we are not plane, and we hardly go on using conventional tem-
complete the definition of the characteristic polyhedron plates.
related to each surface segment. TOOLING DESIGN - The shape of the stamped panels
After computation, which takes only 10 sec, we obtain now being defined with numbers instead of drawings, tooling
the punched tape that will supply information to the milling engineering makes use of the data for lofting and, particu-
 Downloaded from SAE International by University of Birmingham, Monday, August 20, 2018
larly, for finding the most convenient tilting angle. In most
cases, auxiliary surfaces of the tools can be numerically
defined, but we do not know whether it is always worth-
while.
TOOLS MACHINING - The exclusive use of numerical
control to machine stamping tools is not really an easy solu
tion, and we are doubtful about the profit. It would mean
that all auxiliary surfaces (blank holding faces, shear-lines
etc.) should be defined numerically, and this would create
many difficulties. When we are beginning tooling, these
surfaces often have to be modeled in plaster or plastic to
see how the blank behaves.
We have adopted an intermediate process that stands b e -
tween copying and pure numerical control methods - - the
tool model is made up with one element of the master fitted
with ancillary surfaces. It is then placed on the table of
a scanner (Fig. 17) and the feeler center motions are regis-
tered on a punched tape by means on the coordinates of a
certain number of points. This tape is then read by a mill-
ing machine fitted with an interpolator, the tool of which
duplicates the course of the feeler. The stamping tool is
then finished by hand.
POSSIBILITIES
This system may solve most of our problems without any
need for more than five functions. This number would have
to be increased to deal with more complicated cases, such
as may arise in aircraft or shipbuilding.
Theoretically, it would not raise much difficulty; but,
on account of the amount of computation required to obtain
the coordinates of each point of the curve, the speed of the
machine would be reduced, unless we increased the computei
rate. This impediment seems of little importance when
compared with the benefits expected from this method.
SUMMARY
The use of three, four, or five sided character polygons
has given us simple, rapid, and flexible means to define a
large variety of 2 and 3D curves. Exceptions aside, we do
not see any reason for using more vectors. This method is
practical for immediate use of descriptive geometry.
We expect to save time and money in the process of body
design and tooling; moreover, we are aware that the biggest
profit, and the most difficult to predict in figures, lies in
the fact that curves and surfaces will be defined more a c -
curately with figures rather than with drawings, templates,
or masters, the shape of which is not perfect from the start
and is likely to warp or distort with time.
Mathematical curves and surfaces have their own beauty,
and mathematicians feel it more than anyone. But we know
that the aesthetic will never be put into equations. But
body and tool engineers who have to " serve " aesthetics
must remember Lord W. Kelvin' s opinion that one cannot
claim to have mastered a phenomenon until he has expressed
it in figures.
For our part, this is what we endeavored to achieve.
REFERENCES
1. James Fergusson, "Multivariable Curve Interpolation."
Journal of the Association for Computing Machinery, Vol.
11, No. 2, April 1964.
2. Klem M. Jones "The Effect of Mathematical Defini-
tion on Ship Design." Paper presented at Congress of Society
of Architects and Marine Engineers, Santa Barbara, Calif.,
October 1962.
3. Donald A. Atkins and R. Tapia " Mathematical Ship
Lofting. " Paper presented at Society of Architects and Ma-
rine Engineers, Santa Barbara, Calif., October 1962.
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4. Robert W. Feeny, "A Programming System for Nu-
merically Controlled Flame Cutting of Ship's Parts." Paper
presented at Society of Architects and Marine Engineers,
Santa Barbara, Calif., October 1962.
5. M. R. Ward, "The Effect of Mathematical Defini-
tion and Numerical Control on the Production of Ships." Pa-
per presented at Society of Architects and Marine Engineers,
Santa Barbara, Calif., October 1962.
6. George O. Gellert, "Geometric Computing." Machine
Design, March 18 and April 1, 1965.
This paper is subject to revision. Statements and opinions
advanced in papers or discussion are the author's and are
his responsibility, not the Society's; however, the paper has
7. Steven A. Coons, "Surfaces for Computer-Aided De-
sign of Space Figures." Memo MAC - M 253.
8. George Pascoe, "NC at Ford Company." Paper 660151
presented at SAE Automotive Engineering Congress, Detroit,
January 1966.
9. W. L. Johnson, "Analytic Surfaces for Computer-
Aided Design." SAE Transactions, Vol. 75 (1967), paper
670152.
10. W. M. Hogue, "Computer-Aided Design in Body Engi-
neering." SAE Transactions, Vol. 75 (1967), paper 660153.
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