Roof challenge
AIM
For the given Car Roof styling, design and develop the essential flanges and reinforcements, Are in the outer panel, Front Roof Rail,
Rear Roof Rail, Centre Roof Rail and FR and RR Bow-Roofs.
Do a curvature study on the roof and perform calculations for Heat Distortion and Snow load criterion to determine and justify the
position of the Bow-roofs
Do a Section Modulus study for the Master sections created for the Front Roof Rail, Rear Roof Rail, Bow Roof Rails and Centre Roof Rail
Introduction
Roof of an automobile sits above the passenger compartment. Roof houses the vehicle as a shielding part, which safeguards the
occupants from sunlight, heat, rain, wind, dust and other external elements. In case of convertibles, it is called the hood.
In the past roof was introduced as cover for passenger compartment but later on, it was also used as a luggage carrier, sunroof and
in recent past years with the introduction of the solar paneled electric vehicle got a major boost in the automotive industry.
Roof has the following functions
Protects from external damage
Act as a safety gear when a roll-over accident occurs
Luggage carrier
Design of the roof also affects in giving aerodynamic shape to vehicle,
Sunroof
Solar paneled roof in EV
Since the roof has numerous functions. Therefore, the roof has to be stronger enough to withstand the damage experienced by it
while roll-over. For that, the roof should have good strength and stiffness. So, the roof is made with embosses and some
reinforcements, such as
Front roof rail
Rear roof rail
Center roof rail
Bow roofs
They are bonded with the roof through the spot welding and mastic sealant.
While designing the roof, few criteria should be followed, they are visibility, headroom clearance, heat distortion, snow load, curvature
study.
Outer panel area is provided on all the four sides of the roof. Roof outer panel areas are provided to mount roof to the main body of the car also to mount windshield glass for the front outer panel area, and to mount tailgate to rear outer area
OUTER PANEL
The outer panel is shown in the figure.i created this outer panel with the help of input
and also i used the some tools to make in solid .the first step is extract and input and offset in the component thickness of 0.75
in the inner body.
Main-roof is modelled using the styling surface as reference, then the ditch area and emboss are created on it.
The thickness of Main roof is 0.75 mm.
Commands Used:
Offset, plane, Sketch, project, split, sweep, extract, fill, join, edge fillet, extrapolate, symmetry,
extrude, healing, thicksurface, etc.
Emboss over the main-roof
CENTRE ROOF RAIL
central roof rail helps in providing effectively support to the flat area of the roof as it is more susceptible to failure under the action of
load .
generally central roof rail is placed at the center of the roof which is connected to the B-pillar support structure.This central roof rail helps in adding
the strength to the roof during the rool- over test. The thickness of the central roof rail is 1.25 mm
WITH SIDE FLANGE
The side flage is developed with the the help of extract and offset the extract into 1.7 mm and split with plane with required distance and
and using the multi section on flange and center roof rail and also shown in the figure
FRONT ROOF RAIL :
Front roof rail is the one which joins the wind shield glass , body side outer and the inner panel also. Here the front roof rail is
designed based up on the master saection given
Tree structure
