X shaped roof profile for small series car-production method

  • Context: Automotive 
  • Thread starter Thread starter marellasunny
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SUMMARY

The discussion focuses on the production philosophy for a small electric vehicle (SEV) featuring an X-shaped roof profile, derived from a body-in-white (BIW) structure designed through topology optimization. The participant seeks to determine the feasibility of producing this roof using either extruded or hydroformed profiles, noting that the VW XL1 is a comparable model. Key considerations include material selection, with carbon fiber and thermoset fiber-reinforced polymer (FRP) mentioned as potential options, as well as the possibility of assembling the roof from components and the methods for joining them.

PREREQUISITES
  • Understanding of body-in-white (BIW) design principles
  • Familiarity with topology optimization techniques
  • Knowledge of hydroforming and extrusion manufacturing processes
  • Experience with composite materials, specifically thermoset FRP
NEXT STEPS
  • Research the feasibility of using hydroforming for complex shapes in automotive applications
  • Explore the properties and manufacturing processes of thermoset fiber-reinforced polymers (FRP)
  • Investigate assembly techniques for composite parts in vehicle production
  • Learn about welding methods suitable for extruded and hydroformed components
USEFUL FOR

Automotive engineers, production managers, and design students involved in electric vehicle development and advanced manufacturing techniques.

marellasunny
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Hi all! I need to decide on the production philosophy of an SEV(small electric vehicle) as a final part of my thesis project. Up until now, I have designed the package layout and body and performed a FE analysis (topology optimization) to arrive at a reasonable body-in-white structure.

I did a topology optimization and received a x-shaped roof structure as the suggestion of BIW(body in white) build. I haven't found any series produced small vehicles with a x-shaped roof structure. The closest that comes to this shape is the VW XL1 (see below). My question is: Is it possible to produce such a roof structure with a extruded profile or a hydroformed profile? All other parts of my BIW are spaceframe manufacturable, its just the roof that i need to decide on. Thanks!

2014-volkswagen-xl1-carbon-fiber-body-parts.jpg
 
What material? Must it be metal?

The VW X appears to be made from 5 carbon fiber parts. Can you assemble the X from components? If so, a thermal press and thermoset FRP might do it.

Or are hydroforming and extrusion the only options? If so can the parts be welded?
 

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