Hood Design

https://drive.google.com/open?id=1_cBrdQO_VLELZbw0V_CUJdoqlwozUysz

Objective:
To design outer panel of Hood with Hem and develop the Inner panel with all necessary reinforcements like emboss definition then positioning of Hinge, striker and create mastic sealant data Information.

Theory:
The Hood or the Bonnet of a car is considered as the frontal BIW enclosure component. Bonnets are designed to reduce air resistance as the air flows around the car. The design of the bonnet is vital since it affects the aerodynamic flow around the car. Apart from this, bonnets are also designed to meet several other requirements. They serve a great deal of purpose in protecting the passengers inside the car and the pedestrians in the event of an accident. It also acts as the cover for the engine.

The hood or the Bonnet consists of the following parts.

1. Hood outer panel
2. Hood inner panel
3. Latch and Striker re-enforcement
4. Hinge re-enforcement
5. Gas stay re-enforcement

Requirements:
Hood Thickness and manufacturing considerations.

• Outer Panel Thickness = 0.75mm
• Inner Panel Thickness = 0.75mm
• Reinforcement Thickness = 1.5mm
• Minimum fillet radius = 3mm+Thickness (example: When thickness of inner panel is 0.75mm we need to maintain minimum fillet radius 3+0.75=3.75mm)
• No sharp corners inside the component
• No curvatures lesser than 5mm
• Small embosses should not exceed the maximum depth of 6mm (staying on the safe side)
• Mounting areas and welding areas need to be flat
• Provide appropriate corner relief on the area of curvature

Functional and Safety Requirements:

The 1^st and most important safety requirement to be considered while designing the Bonnet is the frontal collision requirements.
The design intention of the hood according to the frontal collision requirement is that the hood crushes and dissipates forces in the upward direction and to the hard points on the hood thereby deflecting the force on to the body and not the passengers.

The second major function of the hood is the opening and closing of the hood. This is done with the help of the latch and striker. To position the latch and striker effectively, we first position the hinge and draw the hinge axis. Now, using the hinge axis from the centre we draw a big circle to the position there we need to place the latch.

Procedure:

1. Master section creation:
   The master section is created based on the requirements received from the marketability team and the manufacturing requirements that we saw before. Below are the images of the master section used for the design.

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1. Geometry and Emboss creation:
   The geometry is created based on the master section that was provided above. After performing the initial stages of design, we will provide local embosses to strengthen the component. The component will be strengthened based on the master section. When a force impacts the hood from the front, it travels in an upward direction. The component is designed to divert the force away from the passengers into the hinges, as shown in the image below:
   Embosses in the inner panel are made according to the diversion of the load path. The emboss depth is kept at a maximum of 5mm to be on the safer side so that the part can be manufactured without any problems.
2. Latch and Hinge reinforcements:
   While the development of the inner panel for the hood, we also need to develop some additional reinforcement’s plates for strengthening the area where we are adding the Latch and Hinge parts. These re-enforcements are made from sheet metal of thickness 1.5mm.

See the below picture where the Latch, striker and Hinge are assembled for your reference.

4. Provision for Mastic Sealant:
The Mastic sealant or the Mastic point is an elastic compound that behaves like a rubber. The mastic points are defined on the hood inner panel where the hood can easily deform. They help the hood outer panel to come back to its original shape after it gets deformed. The mastic has an influence area of 80mm.

1. Hemming and Corner Relief for the Outer panel Design:
   Hemming is the process of joining both the outer and inner panel together. The hemming process roles and wraps the hood outer panel around the inner panel and holds it tightly together. The gap between the hemming flanges of hood outer panel to inner panel will be filled with sealants to make the joint as waterproof. After the hemming is done, we need to provide corner relief at the corners of the hood so that the part can be produced without defects. See the below picture for the reliefs provided at the corners.
   
   *Hemming:
   

*Coner Reliefs:

Conclusion:

I have learned to design a hood that satisfies the industry’s manufacturing requirements, functional requirements and as well as Euro NCAP standards. To develop Hood design I used software Catia V5.