Masters Certification Course on Automotive BIW Design and Development

Masters Certification Course on Automotive BiW Design and Development

  • Domain : DESIGN
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Program Outcomes

Your average car comprises of sheet metal components that are joined together to form a shell. This assembly of sheet metal components is called the Body in White(BIW) of your automobile. The BIW Components of your car include the Roof, Hood, Side doors, Fenders etc. They play an important role in providing structural rigidity and aesthetic appeal to your car. 

Through this Masters’ Program, Skill-Lync has assembled a set of courses to make you proficient in designing and developing BIW components of an automobile. This program consists of 6 courses. This includes a separate course to introduce you to the tool that we use, which is NXCAD. This can be the first course if you choose to do so.

The next course introduces you to the basic concepts of Gap and Flushness. This is an important concept since the automotive body is an assembly of multiple components that could be supplied by different manufacturers. The end product needs to be checked for proper fit and finish.

The Advanced Automotive Body in White Design course gives an outline of the current trends in Automotive sheet metal design. It outlays the fundamental BiW Design factors and detailed explanation of their significance to part function, cost and reliability. This course examines the modern design methodologies and emphasizes how essential, determining product end-use requirements is, in creating successful contemporary products. Through this Masters' course, the student will build all the BIW components of an SUV.

This course has two parts each of 20hrs and 6 projects. The first part will comprise of the Hood,Fender,windshield,Roof,Tailgate and Body side of the SUV.

The second part will comprise the front and rear side doors, floor, frame, dash panel and  engine compartment.

 

Upon completion of these two courses you would have gained a comprehensive understanding of various physical and theoretical design factors and design knowledge of first-rate Automotive BiW components

The next course takes you through the process of designing the jigs and fixtures required to produce the sheet metal components. This course makes use of the tool ,CATIA.

The final course gives you a deep understanding of the crash worthiness of components. The courses prior to this gives you a brief understanding of the crash worthiness practises in the industry but here, you get a deeper understanding and a hands on approach to how this is done virtually using a prominent tool, Hypermesh along with Radioss.

After completing this program, you will be equipped to handle multiple job roles pertaining to BIW design and development.


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What Will You Learn in this Program?

This Masters’ program is a complete package of all the components of a typical BIW Design and Development process. If you are someone who is unaware of the tool that we use, then we have you covered with the basics of NXCAD software that we provide in this package. Then we move you onto the basics of GD&T section. After learning this, comes the BIW part where you get to work on the tool to create each component of your SUV. The final part of the program introduces you to crash analysis practices in the industry using Hypermesh tool.



  • Learn the basics of NXCAD and CATIA
  • Learn about Gap and Flushness in BIW
  • Learn to build the BIW components of an SUV
  • Learn about Crash worthiness

First part of the SUV BIW Components

1Vehicle Architecture

In order to design BiW sheet metal components, it is a prerequisite to have an understanding of the basic structure of a car. This is an introductory session where the student will learn about:

  • The various sub-assemblies of a car
  • Need for 3 zones of a car
  • Purpose of crumple and crush proof zones in a passenger car

2BiW Materials

The role played by materials in BiW component design is crucial. They attribute to the varying cost and weight of the components.

In this session, students will learn in-depth about 

  • The individual components of a passenger car
  • The various materials used for the BiW components such as 
    • Steel(MS,HSS,AHSS,UHSS)
    • Aluminium
    • Magnesium Alloys
    • Carbon Composites
  • Advantages and dis-advantages of various materials 

3Vehicle Development Process

Vehicle development process involves various stages in which the components are manufactured and assembled together.It holds the sequence of operations starting from research study to sales and marketing

In this session, students will learn in depth, 

  • The four main stages of the Vehicle development cycle. 
  • Their sequence, significance and importance. 
  • Car platforms
  • Tophats

4Benchmarking

This is a session that covers the important sub-stage of the Pre-Design and Development stage of the Vehicle Development Process, Benchmarking.

The aim of this process is to ascertain the design and functional features of the vehicle. In this session, two case studies are discussed and benchmarking is performed for alternate designs/products.

5Introduction to manufacturing processes

This session will give the students an overview of various manufacturing processes for BiW components, their types, advantages, dis-advantages are also discussed with illustrations. Processes include,

  • Stamping
  • Deep Drawing
  • Forming

6Design of Hood

In this module,we will focus on the modeling of hood in NXCAD software. The design procedure is summarized as follows:

  • Design Requirements
  • Functional Requirements
  • Euro NCAP Regulations
  • Gap and Flushness Requirements
  • Manufacturability

7Design of Fender

In this module, we will focus on the modeling of fender in NXCAD software. The design procedure is summarized as follows:

  • Design Requirements
  • Functional Requirements
  • Fender Wheel Arch requirements
  • Gap and Flushness Requirements

8Design of Roof

In this module, we will focus on the modeling of roof in NXCAD software. The design procedure is summarized as follows:

  • Design Requirements
  • Functional Requirements
  • Criteria for Bow roof rail positioning
  • Gap and Flushness Requirements
  • Manufacturability.

9Design of Back Door

In this module, we will focus on the modeling of back door/tailgate in NXCAD software. The design procedure is summarized as follows:

  • Design and Functional requirements
  • Backdoor cross sections for sealant flange
  • Tailgate trajectory path
  • Joining process
  • Manufacturability

10Design of Body Side Panel

In this module ,we will focus on the modeling of body side panel in NXCAD software. The design procedure is summarized as follows:

  • Design and Functional requirements
  • Side impact criteria to be considered
  • Roll over test and its significance
  • Joining methods
  • Manufacturability

11Design of Side Door

In this module ,we will focus on the modeling of side doors-front and rear, in NXCAD software. The design procedure is summarized as follows:

  • Side door architecture
  • Special Design requirements
  • Hinge axis, center line and striker position
  • Side door trajectory
  • Bill of materials

12Body side Integration

In this module,we will focus on integrating the body side panel to the body side doors in NXCAD software. The design procedure is summarized as follows:

  • Cross-section study
  • Stack welding
  • GD&T factors concerning integration
  • Sealant flange and surround clearance
  • Integration of body side outer, roof, backdoor and floor


CERTIFICATION

  • Top 5% of the class will get a merit certificate
  • Course completion certificates will be provided to all students
  • Build a professional portfolio
  • Automatically link your technical projects
  • E-verified profile that can be shared on LinkedIn

Second Part of the SUV BIW Components

1Design of floor and frame

In this module we will focus on the modeling of the frame and floor in NXCAD software. The design procedure is summarized as follows:

  •  Front and rear floor assembly
  •  Front floor integration with components
  •  Rear Panel integration with components
  •  Load Distribution
  •  Sealing flange and rubber sealant assembly
  •  Frame assembly and integration
  •  Tunnel assembly
  •  Dash panel and integration

2Design of Engine Compartment

In this module we will focus on the modeling of the engine compartment in NXCAD software. The design procedure is summarized as follows:

  • Various structures of the assembly 
  • Design considerations for each part
  • Manufacturing Constraints
  • List of Connecting members
  • Joining methodology
  • Load path for structures

3Joining Elements

In this module, various joining methods are discussed and compared alongside their advantages and dis-advantages.

Joining methods include:

  • Spot welding
  • Arc welding
  • MIG welding
  • Laser Brazing 
  • Clinching

4Gap and Flushness

Hundreds of components contribute to creating a BiW structure of a car. Each component may be manufactured by different suppliers, in different locations, using varied processes. This means that fit and quality control is vital. Gap and flush measurements are highly beneficial. If fit and finish are out of specification, it affects not only the aesthetics of the product but also the performance, efficiency and increases the risk of failure. That explains the need for Gap and Flushness.

In this session we shall see the,

  • Critical gap and Flushness points of a car
  • Measurement ways
  • Gap and flushness justification of a car

5Geometric Dimensioning and Tolerancing- An Introduction

Geometric Dimensioning and Tolerancing (GD&T) is a quality control method that is used for defining allowable variation in size, form, orientation, and location using symbols. The purpose of GD&T is to precisely define parts and assembly geometry.

In this session, we shall gain introductory knowledge to the following,

  • General dimensioning – merits, demerits
  • Benefits of GD&T
  • Rule #1 – Envelope rule
  • ASME vs ISO
  • Basic terminology explanation – Feature, FOS, Actual mating envelope etc.
  • GD&T Symbols(Geometrical tolerance symbols, modifiers)
  • Explanation: Geometric Tolerance zone & Modifiers
  • Boundary conditions

6Quality- An Introduction

In this session, we will discuss the field concern and methods of measuring quality and quality improvement using case studies. We shall discuss the various global quality advisors. We will perform the following

  • Initial Quality Study
  • Quality improvement case study


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Flexible Course Fees

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Basic

9 Months Access

$199.94

Per month for 10 months

  • Access Duration : 9 Months
  • Mode of Delivery : Online
  • Project Portfolio : Available
  • Certification : Available
  • Individual Video Support : 8/Month
  • Group Video Support : 8/Month
  • Email Support : Available
  • Forum Support : Available
Premium

Lifetime Access

$333.23

Per month for 10 months

  • Job Assistance : Lifetime
  • Master's Assistance : Lifetime
  • Access Duration : Lifetime
  • Mode of Delivery : Online
  • Project Portfolio : Available
  • Certification : Available
  • Individual Video Support : 24x7
  • Group Video Support : 24x7
  • Email Support : Available
  • Forum Support : Available
  • Telephone Support : Available
  • Add-ons Industry Projects : 15
  • Offline Skill-Center Access : Available
  • Dedicated Support Engineer : Available
  • Paid Internship : 3 Months

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Frequently Asked Questions

1Who are the instructors and what is the learning process?

Our instructors are industry experts who are working or have worked in Fortune 500 companies. We also partner with academicians who help us craft course content that will best help our students get recruited and start adding value for their organization from day one.
Our course content is pre-recorded. You will be given access to this content immediately after you have enrolled in our course. Alongside the course videos, you will also be given assignments each week. You will work on these assignments and have it evaluated by our technical support engineers. Apart from this, you will also work on industry-oriented projects that will improve your understanding of the various tools used in the industry and their underlying principles. 

 

2Are there any prerequisites for this course?

You should be pursuing or have graduated with a B.E/B.Tech in Mechanical or Automotive Engineering.

3What kind of support I can expect? What if I have doubts?

Our team of dedicated Technical Support Engineers are always available to answer any queries you might have when you are studying. Studying online courses on your own often comes with the problem of lacking motivation, our Technical Support Engineers will work with you to ensure that you complete the course work and start working in the domain of your interest.  


There are a number of ways through which you have your query answered.
You can ask your questions by raising tickets from your student window screen, and a technical support engineer will respond and help you achieve conceptual clarity. If you did not understand the solution, you can request the technical engineer to share their screen with you and they will explain the areas that you find difficult. Apart from this, you can also send us an email, which we will respond to in under 24 hours. You can also call us at our helpline number - which will be provided once you have enrolled in a course. 


We also have group doubt clarification sessions, where you will interact with your fellow batchmates. This will allow you to understand the different ways your fellow batchmates are using to solve a question. Besides this, you can also raise your queries through the Whatsapp number that will be made available to you. 


4How is this different from what I learnt in college?

The course that you studied in college was designed years ago and does not take into account the current market trends or what the industry expects from graduates. Our courses have been designed in consultation with industry experts and leading academicians. Skill-Lync courses are geared to help you find employment as soon as you complete the coursework. This is possible only because of the projects that you will complete as part of your curriculum, in your college you might have done one major and one minor project. But, each module in a Skill-Lync course has a corresponding project, and these projects are industry-oriented. Which means that if you were to look at the project that an engineer at a top OEM is working on, it will be similar to a Skill-Lync project, the only difference being the scale of the project. 

 

Simply put - there's a world of a difference between what you have studied at your college and what you will get trained in when you study at Skill-Lync. 

5What advantages will I gain by taking this course?

You will have an edge over your peers by working extensively on industry-relevant projects, practice on tools and software that will set you apart and help you in getting ahead of the competition. Along with this, when you enroll in a Skill-Lync course you will get access to the Skill-Lync Student Success Team - who will ensure that you get placed at the end of your course. They will help you polish your resume, and help you properly present your projects on your LinkedIn and other external pages. They will also scour for any opportunity that you might be qualified for and help you apply for it. After which they will train you in all the possible variations of interview questions. The Student Success Team will also train you in tool tests, in which your comprehension of all the tools that you have studied in the duration of the course will be cemented along with the underlying principles.

6What is Body in White (BIW)?

 Body in White refers to the stage in the automobile manufacturing in which a car body's components have been joined together, using one or a combination of different techniques: welding, riveting, clinching, bonding, laser brazing, etc.