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

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 

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

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.

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

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

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

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.

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

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

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

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

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

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

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

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

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

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