How to start BIW design using styling data

In this tutorial my intention is to create rough envelop of BIW of front hinge near the door part. THis tutorial uses styling data which is class A surface.

  1. Step 1:

    This is an extract of class A data . The process will show you how to develop biw sheet metal from simple cad data

  2. Step 2:

    Create a pad of 100mm in upward direction

  3. Step 3:

    Apply a draft angle of 5 degree on side face as shown below

  4. Step 4:

    Apply a draft of angle 6 degree on front face as shown below

  5. Step 5:

    generate a variable fillet which vary linearly from 80 to 100mm

  6. Step 6:

    Insert a body named STEP and create a sketch as shown below

  7. Step 7:

    Using sketch profile produce a PAD of first limit=50mm secound limit=260mm

  8. Step 8:

    Define the work object in to the main body. Generate a extrude from tyre profile. Generate split as shown below

  9. Step 9:

    Create a split planes as shown below

  10. Step 10:

    Create a split planes as shown below

  11. Step 11:

    Define body STEP as work object. Now try to split the STEP with both the plane. The resultant geometry in shown as below.

  12. Step 12:

    Create a new body named STEP FLANGE. Using position sketch orient as show below

  13. Step 13:

    Use project 3D elements and generate a profile as show below

  14. Step 14:

    Using the generated profile pad it for 35mm

  15. Step 15:

    Use thickness option and select the face as shown below and apply a value of 1.5mm

  16. Step 16:

    Apply chamfer of length.1/length.2 as 1 mm & 2.5mm

  17. Step 17:

    using boolean operations add STEP FLANGE body to STEP

  18. Step 18:

    Create a plane using offset from face and offset value as 0mm

  19. Step 19:

    Split the entire part body using the generated plane

  20. Step 20:

    Apply shell of 1mm thickness to selected faces as shown below

  21. Step 21:

    The BIW envelop of Fron hinge is shown below

  22. Step 22:

    In the process of develop Biw you to define the physical relationship between designed component & mating part using typical section which design allowable tolerances as shown below.