Roof Design

Roof Design

The Roof design has been developed from the provided input surface and the master section provided.

Roof Outer

The flanges are developed for the Roof Outer

Draft Analysis:-

Draft Analysis is done with y-axis as the tooling Direction.

Seperate tooling axis is created for the flange in the rear side of Roof Outer

Front Roof Rail

Front Roof Rail is created as per the Master Section provided.

Draft Analysis is Done with y axis as the tooling direction

Rear Roof Rail

Front Roof Rail is created as per the Master Section provided.

Draft Analysis

Draft analysis is done on the Rear Roof Rail with y axis as the tooling direction.

Center Roof Rail

Ceneter Roof Rail is developed according to the Master Section. The projection for the Mastic for joining with the Roof Outer Panel is also designed .

Draft Analysis:-

Draft Analysis is done on the Center Reinforcement Rail with y axis as the tooling direction./

Bow Roofs

Considering the curvature, and length of the roof, two bow roofs are designed. One between the Front Roof Rail and Center Reinforcement Rail and the other between the Center Reinforcement Rail and the Rear Reinforcement Rail. The bow roofs are designed as per the Master Section Provided. The projections for Mastic to join with the Outer Roof Panel is also designed on the bow roof.

Draft Analysis:-

Draft Analysis is done on both the bow roofs with y axis as the tooling direction.

Bow Roof 1

Bow Roof 2

Roof Assembly

Bow–Roof Prediction Study

The Bow Roof Prediction Study is conducted on the Design as given below and the result is OK

Bow	Rx	Ry	R	l	L	t	R**2/t	W	OK
FR to 1st	5757.97	2554.21	3538.67	370.18	1138.8	0.75	16696247	0.0048	yes
1ST to CTR	4980.94	6071.82	5472.55	425.78	1087.17	0.75	39923712	0.4	yes
CTR to 2nd	3985.08	11053.75	5858.18	425.8	1058.40	0.75	45757697	0.47	yes
2nd to RR	3285.31	16360.20	5471.82	347	1044.14	0.75	39921085	0.246	yes

For all the cases, W<2.7