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Math Data Tolerances & Design Center Deliverables Internal Surface Quality Surface Continuity & Quality Fillet Flow Paths Surface/Part Harmony and Part Interface Considerations Engineering /Manufacturing Criteria Compliance Engineering /Manufacturing Die Pull Compliance Design, Quality and Verification Audit
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Meeting or Exceeding the above release standards is the goal for all math releases.
Reference NOA #033 for additional guidelines on release data for IDR and VDR Reference NOA #052 for Examine Geometry guidelines for surface and solid verification.
therefore, it is essential that we provide them with math surfaces that facilitate efficient development of a solid model.
Primary Surfaces
Primary Surfaces should be built to or beyond the region of theoretical intersection. The resultant intersection line should be evaluated to confirm the quality and compatibility of the primary surfaces.
The shape of the intersection line directly influences the fillet shape. Care should be taken to prove out this critical line prior to fillet development. Intersection curve with curvature combs Note: Framing and overbuilding permits greater flexibility with future fillet changes.
The Fillet (yellow) should be curvature or tangent continuous to the primary surfaces, and be built beyond the part perimeter similar to the Primary surfaces.
To help in the Development of the Final Part, the following things must occur:
Primary Surfaces should be built to or beyond the region of theoretical intersection. This permits greater flexibility for change and highlight control for fillets Surfaces should produce predictable extensions without any unusual results (e.g.: monkey tails or spirals)
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This allows downstream modelers to create extensions for the development of solid models, tool addendums, jigs, and fixture needs. Surfaces should be trimmed to internal boundaries and be sewable/stitchable. This provides the desired data used for trimming solids Surfaces should be capable of being offset by a nominal material thickness. Small Fillets or Radii will be the exception if the Fillet Radii are smaller than the nominal material thickness. The capability to Offset surfaces allows for the development of inner panels and backside material thickness. Surfaces should be built beyond the part perimeter This minimizes the possibility of having to rebuild surface because of changes to an opening line, joint line, or edge of part.
Trim Sheets
Rear Door Panel surfaces shown in Wire Frame Display Red curves represent part perimeter trim sheets.
Before Trims
After Trims
Shaded door panel, before and after trims are applied using trim body.
Part with Perimeter Trims 3 Trim Body Features are applied on the Sewn Sheet. Thicken the sewn sheet to create a solid body. Next run Examine Geometry on the solid for verification. Ref. NOA #052
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Part Perimeter
Step 1 Have Class-A Surfaces Trimmed to Adjacent Boundaries, Sewn and Built beyond the Part Perimeter. It is a good practice to run Examine Geometry on the sewn sheet to detect any possible problems with the Class-A surfaces.
Extrusion Curves
Step 2 Use the Sewn Class-A sheets (Blue) to trim a Solid Body (Yellow). This solid is created by extruding a set of profile curves. The solid body should be created beyond the perimeter trim sheets.
Trimmed Solid
Step 3 - Hollow the solid body (yellow) to the desired material thickness. All radii should be larger than the material thickness.
Step 4 Use perimeter and opening trims to define the final part.
Hollowed Solid
Trimming sheets
Step 5 Run Examine Geometry to help validate the math of the Part. The solid should pass all checks denoted in the NOA #033 for Design Center deliverables.
Final Part
The misinterpretation of surface quality can sometimes be a result of improper tessellation. If a surface or boundary condition between surfaces is in question, an extra fine tessellation may be necessary in order to make a valid judgement of the surface quality. Guidelines for Tessellation in Surfseg and Evalviewer Desired Analysis Tessellation Value Exterior and High Gloss Finishes(interiors) Interior Trim and GrainTextured Parts Die Pull/Draft Angle Check or Interference/Clearance Check 0.02 mm 0.05 mm 0.15 mm
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The following images illustrate several different types of surface analysis methods which all support the findings of an internal surface quality issue. The adjacent surfaces leading into this area are of acceptable quality. The issue at hand is the inconsistent flow or transition of the highlight from the lower portion of the A-Pillar to the area above the top of the mirror patch. Analyzing the highlight on the shaded model doesnt show the surface problem as well as the other analysis displays. Surface Issue Area
Highlight Transition
Inconsistent Radius of Curvature Color Maps support Reflection Line displays above
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Also, considerations need to be made pertaining to the amount of time needed to make the correction and whether the correction will be value added. Localized changes can generally be resolved easily, but there are cases where a subtle change can propagate through an entire panel and a majority of its surfaces. Generally when a primary surface change is made, it will drive several surface changes. The location of a surface imperfection should also be considered. If the problem is in a low visibility area, the surface correction may not be made, or more attention may be spent on correcting surfaces located in higher visibility areas.
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V-direction U-direction
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Curve Continuity
The following images show curvature combs, which help detect the curve relationships between two curves. The most desirable condition is a curvature continuous relationship. In some cases, tangency will only be attainable and is also acceptable. Continuity Conditions between Curve Endpoints
Non-Positional
Positional (C0)
Tangent (C1)
Positional (C0)
Tangent (C1)
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The continuity constraints applied to the mating surfaces depend on the design intent, but generally curvature continuity is most desirable. However, imposing surface boundary constraints to obtain tangency or curvature continuity at the expense of internal surface quality is ill advised. Surface Boundary Noise caused by Constraints from adjacent surfaces
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Surface Patches
Excessive numbers of surface patches must be avoided. If not, it invites increased problems with curvature continuity, adjacent surface checks, gaps, highlight separation and possible oscillations between surface patches and within their interior.
Multiple surfaces
Cutting a clay model is a valuable design verification tool to help identify possible surface imperfections, but it may not expose subtle surface quality problems that become major problems at the DIE MODEL cutting stage.
Secondary surfaces should be curvature continuous, but where it makes sense, tangent continuous fillets are acceptable. The following math data conditions lend themselves to creating tangent continuous fillets instead of curvature continuous fillets: 1) The Size or Width of the Fillet from Tangent line to Tangent line Generally very small fillets only need to be tangent continuous 2) The Direction of the Primary Surfaces Primary surfaces that curve the same direction as the fillet being created can alleviate the need for a curvature continuous fillet. 3) The Lead-in of the Fillet Having a longer lead-in on a tangent fillet helps soften the surface transition and the highlight. 4) The Area of Visibility If the fillet surface is going to be in a low visibility area it wouldnt be necessary to spend additional time and effort to make it curvature continuous.
Section Curves with curvature combs show the continuity between the Primary and Fillet surfaces. (G2 continuity)
Colored Reflection Lines are used to observe any subtle or major surface breaks along adjacent surface boundaries.
A Gaussian Color map is displayed to observe the interior surface shape and also the surface flow across the fillet tangent Gaussian Analysis
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When building a fillet with curvature continuity, expanding or offsetting the tangent curves usually is necessary to attain curvature continuity and to hold the fillet shape.
Tangency
Reflection lines showing the results of using the yellow boundary curves for building the fillet surface.
Curvature
Reflection lines showing the results of using the red curves for building a curvature continuous fillet surface and matching the tangent fillet shape.
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Curvature Fillet
Inflection Pt.
Section A-A A
Inflection Pt.
The following images show Curvature Continuity over the Wheel Opening
Reflection lines showing the smooth transition of the Curvature Continuous Fillet Surface. S-shaped reflection lines are generally more desirable in these areas.
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The practice of framing surfaces to create intersection lines is an essential step in controlling fillet highlights and flow paths in primary slabs and major fillet surfaces. However, in many instances, it does create unexpected problems with fillet misalignments and waviness because of the changing included angles in pockets or flanged parts. This is especially true when smaller fillets are applied that do not undergo the chordal flow line or highlight refinements of larger primary fillet surfaces. These very predictable conditions have always existed but were obviously corrected at the hard model or die model stage if they were objectionable. Though usually confined to small detail type fillets, they often reside in high visibility areas and in a full math process, the following sample situations must be anticipated and incorporated into the design. Typical Fender, Hood, and Headlamp Condition Incorrect Flanging Correct Flanging
Common Intersection
Typical sections and fillets must be applied to openings before surfacing is completed
Misalignment
Correct Alignment
Incorrect
Correct
Theoretical Slab Surface Creates Constant Fillet Highlight
Variable intersection
A Constant Intersection and Fillet will produce an erratic Fillet Highlight due to the changing angle.
The Fillet Highlight should be controlled by a Theoretical Slab Surface constant to the door glass.
Typical Door or Fascia Rub Strip Condition Using a Common Intersection Line will create an inconsistent fillet to fillet highlight condition The intersection must vary in order to maintain a constant fillet
Incorrect
Correct
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A BRIDGING SURFACE can be created across the fillet high point that will not only provide a torsion free or twist free surface, but will become the foundation surface for all adjacent details or constant offset controls. The quality of the surface inside the void or data free area can be allowed to wander as long as it produces good results in the adjacent detail regions. A simple offset of a surface and an opening line will now ensure consistent detail relationships. Example of Bridging/Control Surfaces I/P Trim Plate
A Put in 2 images A
Contact Area
Bridge Surface
Contact Area
Contact Area
Contact Area
Exploded View
Controlling peaked fillets where no normal surface is available to provide intersection control needs special attention. An example of this is the eyebrow of an Instrument Panel Cluster Hood. The critical control line would be the high point of the fillet as it wraps around the cluster opening, but no normal surface exists to provide the control needed. A ribbon or fence surface that just 'kisses' the highlight is an option, but there is a strong likelihood that the ribbon surface will twist and will offer little benefit if used for adjacent part detail, (i.e. constant offsets and groove control).
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These are the Evaluation Procedures: The First Evaluation Panel and Feature Continuity Check The Second Evaluation Continuity between and within Adjacent Surfaces The Third Evaluation Overall Harmony
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Part-to-Part Interface
Feature Endings
Fillet Transitions
Groove Conditions
The team also evaluates the released panel for rat holes and discontinuity between adjacent panels. If the team identifies an area of concern or an unusual surface characteristic during the aesthetics / harmony evaluation, they will request that the Design Supervisor or Design Release Engineer compare the findings against the clay or math to seek studio confirmation of the surface characteristics in question.
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It is sometimes difficult for the evaluator to determine whether the surface curvature should be accelerating / decelerating (peaks & valleys) or changing direction (ogees). What may appear to be a surface undulation, may have been a product of the design intent. In most cases, the evaluator needs to review the Clay or Math Model with the appropriate Studio personnel before judging the curvature characteristics of a panel.
Visibility Issues
Close analysis is necessary to identify surface imperfections and in most cases the CAD surface modeling tools are available to make corrections. What needs to be considered is whether the correction is cost effective and /or value added. Generally the location of the imperfection will determine the need for the correction. LOW VISIBILITY AREAS Less Stringent tolerance checks Interiors I/P Endcaps Lower Knee Bolster Center Console Areas Between Seats Exteriors Moldings, Claddings and End treatments tucked in Pockets Obscured View Areas on Fascia Openings or Underside Surfaces Lower Rocker Panel HIGH VISIBILITY AREAS - More Stringent tolerance checks Interiors High Gloss / Zero Grain injection molded plastic parts Upper and Front Surfaces on I/P Exteriors All major panels especially Hoods, Fenders, Quarters, Doors and Deck Lids
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2
Inconsistent fillet relationship
Issue Number
4 Speared Beads
3 Speared Beads
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Issue Number
2 Inconsistent Fillet Relationship & Poor Highlights It is very important to establish consistent relationships between both internal design features and adjacent parts alike. Poor part to part relationships can seldom be corrected or compensated at the vehicle assembly stage. The fillet on the I/P pad yields three different appearances as it tracks around the Trim Plate. The inconsistent fillet highlight is clearly caused by a lack of intersection control and a varying fillet shape.
Radial sections showing inconsistent Pad to Trim Plate conditions (red circled area). Sections are rotated to show similar orientations.
Section B
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In the case below, the dominant fillet tracking around the periphery of the cluster trim plate shows severe waviness due to the absence of a proven intersection line controlling its flow. Wavy Highlight Area
The wavy highlight on the fillet surface is a result of the primary control surfaces. If the theoretical intersection had been proven out this condition could have been avoided.
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Issue Number
Left Side Cluster Wall Narrower
The Inner Walls of the Cluster are not consistent from side to side. The imbalance is visibly noticeable and was detected in an Audit. Whether such an issue undergoes correction would be determined by the amount of time needed to do the fix, the visibility level of the region, or whether other areas deserve more attention, such as Issue #1, the highly visible groove inconsistency.
Vertical Section
The Vertical section shows a change in surface direction, which helps identify the bump in the side wall surface. By eliminating this bump in the surface, the two inner walls will reflect a more consistent look to one another.
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2.0 mm gap
2.0 mm gap
5.0 degree draft 7.0 degree draft 2.0 mm gap 2.0 mm offset
2.0 mm gap
Right
Section after manufacturing concerns are considered. Changed Details of the design will affect the part highlights and design time.
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The illustrations below show the partial scope of eventual design criteria that is factored into a production release. If requirements are not met, many related surfaces will have to be redone following a Design Center release. TIME SPENT DEVELOPING NON-CONFORMING DETAIL SURFACES WILL BE TIME WASTED. Insert Previous document sections
The pictorial & sections illustrate the Production Engineering requirements per Platform Engineering Center. Deck Lid adjusted to be under-flush with Quarter to hide side view opening lines. Tail Lamp has been constructed under-flush with Quarter to prevent building proud of surface at assembly. License Pocket Applique is designed to be under-flush with Deck Lid surface. All gaps between adjacent parts constructed to Engineering approved typical sections. Overslam requirements factored into the contour of Deck Lid surface. All pockets and flange conditions satisfy required Die Pull and Draft Angles - 31 -
Tapering blend conditions applied between Tail Lamp and Deck Lid to comprehend varying offset dimensions.
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Draft Angle Analysis Die Lock Area 5 Degree Draft (Blue Area in Violation)
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Not all component designs permit part withdrawal from tool simply with the application of a draft angle. If the surface reverses on itself in the direction of draw, then a parting line is necessary to allow for two-part mold separation. This line becomes as important as any design feature line on the surface because it will be noticeable on the actual part itself. Therefore, care must be taken to generate a precise parting line to be used as the foundation for draft angle takeoff.
Simple component parting lines such as armrests, handles or knobs and buttons present little challenge, but more complex shaped parts such as Pillar Garnish Moldings, Outside Rear View Mirrors or Steering Wheel Spokes deserve special consideration to ensure there is no surface rebuilding required at the Manufacturing or Supplier stage. Many times a parting line can be represented as an intentional design feature line, thus simplifying the parting process. If this is not possible, then the high point or silhouette line becomes the mold separation point and this line must be a pleasing line that is factored into the eventual surface build. See Steering Wheel illustration that follows. NOTE: Confirm the grain texture of part before design begins. The draft angle used is dependent on grain texture and any change in grain selection will surely impact the eventual design.
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Parting Line
Rim Section
Spoke Section
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