Roof Design

Roof Design:

NOTE: I have attached both a part file and an assembly file. Apologies, as I first created the whole roof as a single part. Then using product interface and wave interface commands, I created separate part files of Bow roofs, front roof, rear roof and center roofs. I have attached all the parts files as well.

Mandatory parts

- Rail roof front

- Rail roof rear

- Rail roof center

- Bow roofs

All the rail roofs are of 1 quantity but it is upto us to have different number of Bow roofs. If the length of the car is

long, then it will prompt us to have 3 Bow roofs sometimes.

Each rail roofs have their own cross section that needs to be followed. The styling team information has all the information on the material it is

made from, the counrty to which it is sold, the thickness.

Always Thicken it inwards as then it meets the required radius which is of 3mm.

Rail roof front:

Made according to the provided master section. The surfaces has to have a smooth finish through edge or face blends. Corners are to smoothed through bridge curve and through the use of Swept command/through curves, we need to create smoother surfaces. The parts are always to be thickened inward.

Rail roof rear:

Similar to front rail, made according to the provided master section. The surfaces has to have a smooth finish through edge or face blends. Corners are to be left as they are. A minimum clearance of 3mm is provided at the ditch area between outer panel and inner cross section for spot weld purposes. The parts are always to be thickened inward.

Bow roofs:

The current sketch contains 2 bow roofs. They are created according to the master sections provided. The surfaces has to have a smooth finish through edge or face blends. The bow roof when joined with the end flat surface has to create a smooth section. They can be created through swept and through curves. The parts are always to be thickened inward.

Center roof:

The current sketch has 1 Center roof rail. They are created according to the master sections provided. The surfaces has to have a smooth finish through edge or face blends. The bow roof when joined with the end flat surface has to create a smooth section. They can be created through swept and through curves. The parts are always to be thickened inward.

Curvature study:

1) Heat Distortion Test:

A certain load is provided at an angle for a particular duration on the roof. For this test, we will have only BIW and not Tires and any other part. The safety team will then see how the roof reacts to the load.

The curvature study is done to test the radius of curvature at different points and also the positioning of the bow roofs and center roofs. When checked, the values were within the given condition.

Snow Load test:

Dead weights on the roof that will act similar to the snow. Dents will be formed on the roof. we will have to look to see if the dents go back to their original positon if the dead weights are removed.

The conditions were seemed to be meeting the conditions.