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Front Roof Rail Reinforcement Design

This document describes the design of a front roof rail reinforcement using CATIA V5. It discusses the design considerations and available inputs. The methodology involves extracting surfaces from existing models, offsetting surfaces, creating side walls, applying weld spots and notches, adding embosses and holes, and using symmetry and thickening to create the final reinforced part model. The conclusion states that the required reinforcement design was successfully created meeting the given inputs.

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omkar sarkar
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300 views19 pages

Front Roof Rail Reinforcement Design

This document describes the design of a front roof rail reinforcement using CATIA V5. It discusses the design considerations and available inputs. The methodology involves extracting surfaces from existing models, offsetting surfaces, creating side walls, applying weld spots and notches, adding embosses and holes, and using symmetry and thickening to create the final reinforced part model. The conclusion states that the required reinforcement design was successfully created meeting the given inputs.

Uploaded by

omkar sarkar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Assignment Name: Front Roof Rail Reinforcement design Using CATIA

V5

Submitted by: Omkar Sarkar (Design Engineer Trainee June-2021)

Front Roof Rail Reinforcement design Using CATIA V5

AIM: Front Roof Rail Reinforcement design using CATIA V5.

ABSTRACT: This report deals with the steps and methods involved in making of
the Front Roof Rail Reinforcement design using CATIA V5 workbench. It will
discuss the stages and tools that are used all along the design process and will
thus frame the approach of the designer.

INTRODUCTION:

Reinforcements are used in BIW Structures to provide strength and stiffness for
main pillars.

Front Roof Rail structure used for below purposes

• To hold windshield glass


• To hold Front map lamp, sun visor, Headliner mounting
• Frontal crash load path

A frontal crash is the most common crash resulting in a fatality.

Frontal Impact test

Each car tested is subjected to an offset impact into an immovable block fitted
with a deformable aluminum honeycomb face. This impact is intended to
replicate the effect caused in the car when crashing 64km/h 40% offset frontal
crash with a similar mass car.
DESIGN CONSIDERATIONS: -

• Minimum radius = 6t = 6 mm
• Flange length for Spot Weld Area = 14mm
• length of the Reinforcement = 820 mm
• Width of the Reinforcement = 120 mm
• Depth of Reinforcement = 15mm
• Design gap between non welding surface = 3mm
• Trim edge to Radius end = 3mm
• Radius to Radius end in joggle area = 3mm
• Edge to Edge distance for part trim line = 1mm
AVAILABLE INPUT: -

Roof Panel

Front Roof Rail

MATERIAL CONSIDERATION:

• Part material: Dual phase steel - DP590


• Part thickness: 1.0 mm
• Part Weight: 0.71 kg
CATIA V5 GENERATIVE SHAPE DESIGN OPERATIONS USED:

• Extract
• Un-trim
• Split
• Trim
• Extrapolate
• Offset
• Edge Fillet
• Boundary
• Sweep
• Join
• Thick Surface (Part Design Workbench)
Design Methodology

1. Basic Surface Creation


• Using extract command in operations, we get the surface from the
existing model. We take all the inputs that are required to create our
model.

• We have to extract and copy, paste the surfaces. By using paste special
option and when there is no link between the two surfaces to create a
local update. So, all modifications done on the source part are updated
on our part as well.

• Untrimming the surfaces next step after Paste special. This is necessary
to get a proper rectangular or square surface despite any radius or
curvature on the original surface at the time of extrapolating it.
• We extrapolate the surface up to the length required. And we click
on assembled result to avoid the existence of the two surfaces
independently. And the continuity has to be curvature continuity for
the design requirements.
2. Offset surface creation
• The unwanted edges are trimmed. Here we gave offset of 3.
75mm.This is done to avoid any interference between the surfaces.
And thus, we create basic surface required for the reinforcement as
shown below.
3. Side Wall creation
• After we have created the basic surface, we further move towards
creating side walls. Using boundary and sweep command.
4. Operation
Operation consists of using trim and split option getting the desired shape
of reinforcement.
5. Applying weldspot area
• Using point line and parallel curve command weld spot area is
marked on the surface.

6. Applying notch cut


Using point, line and by copy pasting it, finally splitting into desired cut
piece.
7. Emboss and hole creation
• Using circle, sweep and trim command creating the emboss and hole
creation. Finally applying fillets to it.

• Fill command used to create circular surface that acts to be the base
of emboss. Is shown in figure below.
• Wall creation of emboss using sweep command, taking input as circle
and fill as a reference surface.

• Finally trimming the emboss with main body modeled using trim
command. Selecting the desired option is as shown in below figure.
8. Final surface
• Using Symmetry option mirroring the geometry along the plane and
joining them by using join command.
9. Thick surface
• Finally adding thickness to the surface from part design module.

Final model
CONCLUSION: Hence, we have created the required Front Roof Rail
Reinforcement with the given inputs. The section views of the part that we
created is given below. The tree structure at the end is shown as well.

Section View
Tree Structure

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