Section Modulus calculation and optimization

ROOF:

They have given the outer panel where we have to do the design:

• Insert a Geometrical set & name it as Construction.
• Insert another geometrical set Outer panel under the construction.

OUTER PANEL:

• Intially Extract the surface.
• Next step is to Untrim the extracted surface.
• Insert a boundary for the Untrimed surface.
• Split the boundary with the Untrimmed surface.
• Sweep the Split.1\Edge.2 for 21mm & 3deg.
• Sweep the EdgeFillet.2\Edge.15 for 21.5mm & 70deg.
• Sweep the Split.1\Edge.4 for 20mm & 3deg.
• Sweep the Split.1\Edge.5 for 15mm & 25deg.
• Sweep the Sweep.4\Edge.6 for 45mm.
• Sweep the Sweep.5\Edge.7 for 60mm & 90deg.
• Sweep the Sweep.6\Edge.8 for 20mm & 50deg.
• Sweep the Sweep.7\Edge.9 for 20mm & 40deg.
• Sweep the EdgeFillet.2\Edge.14 for 21.5mm & 70deg.
• After finishing all the 9sweeps Extrapolate the sweep.1 surface with Edge1.
• Extrapolate the sweep.3 surface with Edge1.
• Trim the extrapolate 1 & extrapolate 2.
• Join split & trim.
• Edge fillet the join for 10mm.
• Insert a Multi Section Surface.
• Join sweep 2, sweep 9, edge fillet & multi section surface.
• Join sweep 4 To sweep 8.
• Extrapolate join 4.
• Trim join 2 & extrapolate 5.
• Extrude the trimmed surface for about 20mm with Y component.
• Extrapolate the extracted surface for about 93.5mm.
• Split the extrapolated surface with Trimmed surface.
• Apply edge fillet to splitted surface for 4mm.
• Apply the edge fillet for edge fillet 3 for 10mm.
• Apply the edge fillet for edge fillet 4 for 4mm.
• Apply the edge fillet for edge fillet 5 for 4mm.
• The blend corner Edge fillet Face 2 , face 3, & face 4 & st=et back for 5mm.
• Draw 2 planes.
• Intrsect blend corner & plane 1.
• Extract the blend corner edge 10.
• Insert a parallel curve for extract.3 surface.
• Split the Blend corner with parallel curve.
• Insert a corner for 4mm.
• Trim the parallel curve, corner, & intersect.
• Split the Blend corner with trimmed surface.
• Extrapolate the splitted surface.
• Insert a plane
• Split the extrapolated surface with plane 5.
• Symmety the plane & split.
• insert another plane.
• Finally Join the symmetry & split.

• Heat Distortion Has to be calculated according to rhe formulae given.

HEAT DISTORTION CALCULATION:

• Insert a geometrical set & name it as Heat Distortion Calculation.
• In this we have to calculate the heat distortion & the design has to be followed.
• Draw 2 planes Intially.
• Insert a point & Draw a sketch.

• After drawing the sketch we have insert 11 points.
• Then Extract the Join.6\Face.7 which is present in the outer panel.
• Select the projection command & project the sketch with support of extract.
• Insert 8 splines.
• Again insert 3 points
• Heat distotion is completed.

• Next Snow Load has to be designed.

SNOW LOAD:

• Insert a geometrical set & name it as Snow Load.
• Inside the snow load insert another geometrical set & name it as section.
• Inside the section insert another 4 geometrical set & name it as BR1, CRR , BR2 & Calculation.
• The steps will be followed in BR1,BR2, CRR & calculation is shown in the design below .
• Final product of outer panel.

FRONT ROOF RAIL:

• Insert a geometrical set Construction.
• Insert another geometrical set, Front Rails Panel, under Construction.

FRONT RAILS PANEL:

• Multiple Extract Surface.262\Face.2, Surface.263\Face.3
• Extract Surface.297\Face.7.
• Insert 3 offsets for the extracted surface for 32.75mm,5.5mm & 3.5mm.
• Insert another offset for Surface.262 for 1.5mm.
• Extract the offset 1.
• Insert the parallel curve for the extract2 with the support offset1 for 80mm.
• Split offset 1 with parallel curve1.
• Extract offset.2.
• Insert the parallel curve for extract3 with the support offset2 for 80mm.
• Insert the parallel curve for parallel2 with the support offset2 for 15mm.
• Split the offset2 with parallel curve 2 & 3.
• Extract the offset 3.
• Insert a parallel curve foroffset.3\Edge.9 with the support offset3 of 110mm.
• Insert a parallel curve fo extract4 with the support offset3 of 95mm.
• Split the offset3 with parallel curve 4 & 5.
• sweep it fo 36mm & 10deg.
• Design a multi section surface.
• Extract the split.3\edge.13.
• Sweep it for 10mm & 10deg.
• Trim everything from offset 4 to split 3.
• Edge Fillet trim3 for about 2.25mm.
• Edge Fillet , edge fillet 1 to about 5.75mm.
• Edge Fillet , edge fillet 2 to about 2.75mm.
• Edge fillet, edge fillet 3 to about 3.75mm.
• Draw a plane.
• Intersect edge fillet 4 & plane.
• Split edge fillet 4 with plane.
• keep a point.
• Insert a spline.
• Extrude the spline.
• Split split4 with extruded surface.

EMBOSSES:

• Insert a geometrical set under constrruction & name it as Embosses.
• Intially draw a plane.
• Draw a sketch.

• Project the sketch with the support offset1.
• Split the split 5 with projected surface.
• Insert 5 sweeps for curve smooth for 12mm & 8odeg.
• Join all the sweeps with split 6.(join2)
• offset the split 1 for 10mm.
• Insert a parallel curve offset.5\edge.26 with support of offset5 for 10mm.
• Split offset 5 with parallel curve 6.(split7)
• Trim split 7 & join 2.(trim5)
• Edge Fillet the trim5 for 4mm.(edge fillet7)
• Draw a sketch.

• Extrude the sketch for 20mm as Limit 1 & 69mm as Limit 2.
• Split edge fillet 7 with the extruded surface.(split 10)

FINAL

• Create ageometrical set under construction as Final.
• Extrpolate split 10 with boundries edge1 for 15mm.(extrapolate3)
• Split extrapolate 3 with xy plane.(split11)
• Symmetry split 11 with xy plane.
• Join split aa with symmetry2.
• Final Front Roof Rail is designed

SOLID MODEL FOR FRONT ROOF RAIL:

REAR ROOF RAIL:

• Insert a geometrical set Inputs.

INPUTS:

• Extract surface.1\face.1
• Extract surface.7\face.7
• Extract surface.8\face.8

CONSTRUCTIONS:

• Insert a geometrical set construction.
• Insert a geometrical set under construction & name it as Rear Rail Panel.

REAR RAIL PANEL:

• Offset the Extract 1 surface for 1.5mm.
• Offset the Extract 4 surface for 91.5mm.
• Sweep offset.1\edge.8 with Y component for 70mm & 10deg.(sweep2)
• Expolate offset 2 with boundries edge1 for 88mm.(extrapolate2)
• Trim extrapolate 2 & sweep2.
• Insert parallel curve for curve Extract6 & support trim3 for 99mm.
• Split trim3with parallel curve 1.
• Sweep curve smooth 1 for 120mm & 32deg.(sweep 3)
• Offset the surface Extract4 of 4.5mm.(offset7)
• Offset the surface Extract4 of 6.5mm.(offset8)
• Trim offset 8 with sweep3.(trim4)
• Insert parallel curve for the curve Extract & support trim 4 for 10mm.(parallel2)
• Split trim4 with parallel2.
• Sweep curve smooth 2 for 10mm & 10deg.
• Trim offset 7 & sweep 4.
• Insert parallel curve for curve trim.5\curve.6 & support trim5 for 5mm.
• Split trim 5 with parallel 3.
• Join sweep1,2 & 3 with offset 1.
• Draw a plane.
• Split join 1 with plane2.
• Edge fillet split4 for about 4mm.
• Edge fillet , edge fillet 1 for about 2mm.

EMBOSSES:

• Create a point.
• sketch a plane.
• Draw a sketch.

• Extrude the sketch Limit 1 for 20mm & Limit 2 for 24mm.
• Split edge fillet 2 with extrude 1.
• 4 Sweeps for for extracts 12,13, 14 & 15 with split 5 for 12mm & 80deg.
• Extract edge fillet.2\face.18
• Offset extract 17for 10mm.
• Join all sweeps with split 5.
• Trim offset10 with join 2.
• Edge fillet the trim 6 for 4mm.

FINAL:

• Insert a geometrical set Final under the construction.
• Extrapolate edge fillet 3 with edge1.
• Split Extrapolate 3 with xy plane
• Symmetry split 6 with xy plane.
• Join split 6 & symmetry 1.

SOLID MODEL OF REAR ROOF RAIL:

CENTRE ROOF RAIL:

• Insert a geometrical set Inputs.
• Extract the Surface 1.

• Insert a geometrical set Constructions.
• Inside construction insert a geometrical set centre Rail Panel

CENTRE RAIL PANEL:

• Insert a point.
• Insert a parallel curve, curve as Extract.1\Edge.1 & support as Extract.1 for 1012mm.
• Insert a line.
• Project the line with the support of Extract.1
• Insert a parallel curve, curve as Project.1 & support as Extract.1 for 50mm.
• Insert a parallel curve, curve as Project.1 & support as Extract.1 for 50mm.

• Split Extract.1 with parallel 2 & parallel 3.
• Offset split 1 fo 6.5mm.
• Offset split 1 for 21.5mm.
• Insert a parallel curve offset.1\edge.2 & support as offset.1 for 18mm.
• Insert another parallel curve offset.1\edge.3 & support as offset.1 for 18mm.
• Split offset.1 with parallel curve 4.
• Split offset.1 with parallel curve 5.
• Sweep split.2\edge.4 with Y component for 23mm & 7deg.
• Sweep split.2\edge.5 with Y component for 23mm & 7deg.
• Trim offset.2 ,sweep.1 & sweep.2
• Insert a parallel curve Trim.1\Edge.1 & support of Trim.1 for 17mm
• Insert a parallel curve Trim.1\Edge.2 & support of Trim.1 for 17mm
• Split trim1 with parallel curve 6.
• Split trim1 with parallel curve 7.
• Insert 2 sweeps split.4\edge.6 with Y component & split.4\edge.7 with Y component for 23mm & 7deg.
• Offset split.1 for 16.5mm
• Trim sweep3, sweep4 & offset3.
• Joiin all split with trim.
• Edge fillet the join for 4mm
• Insert 2 points.

SIDE JOINT:

• Insert a geometrical set Side Joint inside the construction.
• Extract surface.3\face.3
• Project a Line.1 with support of extract.2
• Insert a parallel curve Project.2 With support of extract.2 for 50mm
• Insert a parallel curve Project.2 With support of extract.2 for 50mm
• Split Extract.2 with parallel curve 8 & parallel 9.
• Offset the split of 1.5mm.
• Insert a plane.
• Split edgefillet.1with plane.
• Add 2 splines.
• Multi section surface offset.12\edge.12 & Multple extract.1 with support offset .4 & split .7 reapectively with tangent continuity with both splines.
• Join split.7, multisection surface.1 & offset.4

CUTOUT:

• Insert a geometrical set CutOut under construction.
• Draw a sketch.

• Extrude the sketch.
• Insert 2 multiple extracts for the extruded surfaces.
• Split the Join.2 with 2 multiple extracts.

FINAL:

• Insert a geometrical set Final.
• Extrapolate the Split.16 which is done in cut out, with edge.1
• Extrapolate the extrapolate.1 with edge.1
• Split the extrapolate2 with xy plane.
• Symmetry split.17 with xy plane.
• Join split.17 & symmetry.1

SOLID MODEL OF CENTRE ROOF PANEL:

BOW ROOF1:

• Insert a geometrical set Inputs.
• Extract the surface.
• Extract the curve 1.
• Extract the curve 2.

• Insert a geometrical set Constructions
• Insert another geometrical set Bow Roof Rail Panel under construction.

BOW ROOF RAIL PANEL:

• Intially Insert a point & a line.
• Project the line.1 with support extract.1
• Insert 2 parallel curves project .1 & support extract.1 for 40mm
• Split Extract.1 with 2 parallel curves.
• 2 Offsets for Split.1 for 6.5mm & 16.5mm
• Insert another 2 parallel curves offset.1\edge.2 & offset.1\edge.3 with the support offset.1 for 15mm
• 2 Splits offset.1 with Parallel curve 3 & parallel curve 4
• 2 Sweeps split.2\edge.4 & split.2\edge.6 with Y component for 20mm & 7deg
• Trim offset.2, sweep 1 & sweep 2.
• Insert 2 parallel curves trim.1\edge.1 & trim.1\edge.2 & support as trim.1 for 12mm
• 2 Splits trim.1 with Parallel curve 3 & parallel curve 4
• 2 Sweeps split.2\edge.7 & split.2\edge.8 with Y component for 20mm & 7deg
• Trim offset.3, sweep 3 & sweep 4.
• Join all the splits with the trim.2
• Edge fillet join 1 for 4mm.

SIDE JOINT:

• Insert a geometrcal set Side Joint under construction.
• Extract Surface.3\Face.4
• Offset extract 4 for 1.5mm
• Project line.1with support offset4
• Insert 2 parallel curves Project.2 & support offset.2 for 40mm
• Split offset.4 with parallel curves 7 & 8
• Insert 2 splines.
• Insert a plane.
• Split edge fillet.1 with plane.1
• Multi section surface split.6\edge.17 & extract.6 with support split .6 & split .7 reapectively with tangent continuity with both splines.
• Join split.6 & split.7 with multisection surface.2

• Intially Insert a point & a line.
• Draw a sketch

• Extrude the sketch , Limit 1 as 20mm & Limit 2 as 32mm
• Split join.2 with extrude 1
• Split join.2 with extrude 1 & extrude 3
• Draw a sketch.

• Extrude the sketch 3 , Limit 1 as 62mm & Limit 2 as 32mm.
• Put a Rectangular pattern 10instances 57 mm spacing, Reference element Z Axis & 2 objects.
• Split , split.8 with extrude.2 , extrude.3 & rectanfular pattern

FINAL:

• Insert a geometrical set Final under construction.
• Extrapolate split.11 with Boundary edge1 for 5mm
• Extrapolate extrapolate.1 with Boundary edge1 for 5mm
• Split extrapolate.2 with xy plane
• Symmetry split 12 with xy plane
• Join split 12 & symmetry.1 with merging distance 0.03mm.

SOLID MODEL FO BOW ROOF:

BOW ROOF 2:

Same procedures followed in Bow Roof 2 as in Bow Roof 1

ROOF ASSEMBLY:

• Open Assembly Design & assemble everthing to get a ROOF assembly

Calculation:

Filname	Size	Action
ROOF AS…MBLY.zip	11.48 MB