The roof is supported by the roof header, which is the main part of the safety-critical roof structure and protects the occupants in a rollover. Materials for roof headers must have a high tensile strength, be lightweight to reduce the center of gravity of the vehicle, be extremely robust, and be easy to integrate.

The current problem for OEMs is to balance vehicle performance, design, and affordability. Furthermore, the car industry must integrate all of these conflicting essential performance elements at a far faster rate than ever before. cheaper materials and thinner portions Body-in-White (BIW) systems have difficulty providing the same/higher levels of performance and quality as earlier versions. Additionally, this paper will focus on this system’s BIW structures, which account for nearly 30% of a vehicle’s bulk and nearly 40% of its cost. It will examine the body’s upper structure, in particular its roof panels.

Almost all small vehicles today have three to four roof bows as part of their structural design. A Roof Bow is a Sheet Metal Component that is often spot welded to the BIW inner frame to create the vehicle body’s inner framework. Its main purpose is to sustain the stresses on the roof panels, including local stiffness and oil can loads. A car with three roof bows was chosen for the study because roof bows only play a minor part in the torsional rigidity of the structure. With the sole intention of adjusting the roof panel’s curvature and/or shape as a controlling factor, to remove one of its roof bows, in order to reduce mass and costs while maintaining at least the same performance levels as previously, without affecting the end product. The area of an automobile that is located above the passenger compartment and shields the occupants from the sun, wind, rain, and other environmental factors is known as the roof or car top. The original autos’ roofs were made of comparable materials and had similar designs because they were developed at the same time as horse-drawn carriages.

Most cars have a roof header that spans the width of the roof, between the right and left roof side rails. The roof header could consist of an elongated reinforcing structure that spans the width of the car’s roof and is attached to the right and left roof side rails at opposing ends. While the roof header might offer width-wise reinforcement to a vehicle body at the vehicle roof, it might also be conceivable to include other elements that boost structural rigidity and offer more weldable surface area.

The requirement for different cars and vehicle roof structures with front header extensions and centre emboss structures that boost structural strength in a vehicle lateral direction results from this.

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