Roof challenge

                                                      REPORT

OBJECTIVE:

        They are provided car roof styling design develop a BIW Roof rail, Bow roof rail, center roof rail and rear roof rail by  following the engineering standards. The roof must be subjected to draft analysis for verifying whether it satisfies the manufacturing requirements. we need calculate the heat distrotion and snow load calculation.

INTRODUCTION:

       1. An automoblie roof or car top is the portion of an automobile that sits above the passenger compartment protecting the vechicle from the sun,wind,rain and other things.

       2. It is also acts as a cross member between body sides of a car body and provides provisions for front wind shield, backdoor. Roof assembly also one among the parts which provide safety for rollover accidents.

DESIGNING THE REINFORCEMENTS:

        1.Ditch area:

                The ditch area of the roof was designed by taking the considerations provided by the styling team. The ditch area was designed to have a mininmum 3 degree of maximum draft angle and 0.75mm thickness. The ditch area is the extended portion of the main roof concealed by other Biw panels. The rails of the roof were attached by using spot welds and mastic sealents. visiblity criteria, Head room cleareance , windshield clearence and back door clearence  also going to be taken in the design consideration of the roof.

     2)Front roof rail.

                  The front roof rail is located in the front of the roof were the wind shield is join with the roof. The visiblity criteria and head room clearance of the passenger are taken in the consideration for the bottom flange one end is join using spot welding while the other end is joined using mastic sealents for a joining process.

3.Bow roof

      Bow roof is the additional stiffening member for the roof to increase the strength and so it can satisfy the standards both the end are used to join mastic sealent to improve the strength and also would not affect the styling surface.

    for creating bow roof we need to take reference from the surface A . The tool name is geomentry wave linker its very use take the referance by using that we are needs to develop the bow roof with respect to the standards.

4.Center roof rail

      Center roof rail or the reinforcement center is located at the center of the roof. The cross section of this is more since it needed to provide more strength to the roof. here both the ends are joined by using mastic sealent.

       The center roof rail is the center parts that we need to create and the width for center roof rail is 80mm to 90mm . the center roof rail has to be bigger one then the bow roof rail so that we can have the sufficent strength to protect the car .

5.Rear roof rail

       This roof rail is join with the back door and the roof. inputs from the back door are taken in to consideration for designing this roof rail. here one end is joining by using the spotwelding and another side is joined by using the mastic sealent 

  we have to use the desigening standards to design the rear roof rails so we can give the efficient space for the placement for backdoor and also for the c piller .

ANALYSIS:

       1.Heat distrotion criteria:

              1.Heat distrotion is the temperature at which the metal is softens and deforms unders a specific load. This study is done to check the ability of the roof  to withstand high temperature with respect to the positioning of the reinforcements which contribute to increase the strenth.

              

       In the heat distrotion criteria my module has passed the standards and good  to go for the furher process and so we can able to maufacture the part .

SNOW LOAD CALCULATION:

       Snow load calculation is the type of study done to check the ability of roof whethwer it can withstand to different temperatures like cold weathers and also from the atmosphere were the snow falls and rebounds to its orginal position when a snow of load is removed. 

 

    From above the results, these values for the snowload values it does satisfyed the condition.

    But we can add the additional strenth for the roof so we can increase the thickness and create the emboss for the roof.
3. section modulus.

    1.Bow roof1

               

     2.Bow roof2

   

     3. Center roof rail.

        

4.DRAFT ANALYSIS:

        1.While designing a component a design engineer must make sure that the component can produced by any means of maufacturing methods with least amount of time , material and manpower. so that we can reduse over all cast of a car.

        2. In NX draft analysis can be done after modelling so that we can verify whether the manufacturing by pressing or not.  one surface can be highlighted by green and other side by red colour means that the model can be manufactured

        3. draft means which is essitential for creating a product basically the draft is angle . so by using the angle we can able to remove our work piece or finished product saftely with out damage from the operation of making components.

  Results of draft analysis shown in figure:

ROOF:

2.Front roof rail:

3.Bow roof:

4.Center roof rail.

4.Rear roof rail:

Conclusion:

    1. Thus the required Ditch area,Bows and reinforcement for the roof were designed and developed from the given class A surface.

   2.calculations for the heat distrotion and snow load predections were also performed

   3. The Biw roof of a car was designed and achieved.