Numerical investigation of thermal buckling and post-buckling behavior of an EN AW 6016-T4 car roof assembled in a steel body-in-white

The automotive industry is undergoing significant changes driven by factors such as reducing carbon dioxide emissions, advancing technology, evolving regulations, and the emergence of new energy sources. Lightweight materials, particularly aluminum alloys, are being extensively researched and integrated into vehicles to reduce weight and improve performance. However, the heating process during vehicle production can cause thermal buckling in thin aluminum alloy structures, affecting their appearance and quality. While thermal buckling has been studied in other industries, research in the automotive sector, particularly for non-structural parts like car roofs, is limited. This study uses numerical simulation to predict thermal buckling and post-buckling behavior of a EN AW 6016-T4 alloy car roof assembled in a predominantly steel body-in-white. The research findings indicate that roof buckling occurs at a relatively low temperature difference of approximately 60 °C, which is lower than the maximum temperatures experienced during the painting phases in the automotive industry. Consequently, undulations in the roof's shape become apparent, underscoring the importance of design modifications to ensure visual conformity. Validation through physical testing confirms the model's accuracy, providing valuable insights for designing lightweight structures with improved performance and aesthetics.