Week 2:- BiW Fixture Basics Challenge
BIW FIXTURE BASIC
2. What are the types of joining processes?
INTRODUCTIO
➢ The durability and performance of any structure is largely dependent on
the quality and the design of the component joints.
➢ Whole structure can not be made in one piece.
➢ Two fundamental options for joining materials and component
Mechanical joining
Metallurgical joining
3.What is Resistance Welding & its application in the automotive sector?
❖ Resistance Welding
• Resistance welding is welding technology widely used in manufacturing industry for
Joining metal sheets and components.
• The weld is made by conducting a strong current through the metal combination to
heat up and finally melt the metals at localized points (s) predetermined by the design
of the electrodes and /or the workpiece to be welded.
• A force is always applied before, during and after the application of current to confine
The contact area at the weld interfaces and, in some applications, to forget the workpieces.
❖ Type of resistance welding
1. Resistance spot welding
2. Resistance seam welding
3. Resistance projection welding
❖ Resistance spot welding
• The process is used for joining sheet materials and uses shaped copper -or zirconium
alloy electrode to apply pressure and convey the electrical current through the workpieces.
• Heat is developed mainly at the interface between two sheets, eventually causing the
Material being welded to melt, forming a molten pool, the weld nugget
• The molten pool is contained by the pressure applied by the electrode tip and
The surrounding solid metal
Advantage
▪ Short weld time and hence high weld speed
▪ Highly adaptable to automation and robotic techniques
▪ Typical BIW contains 5000 welds
▪ Strength and durability of automobile largely depends on quality of RSW
❖ Resistance Seam Welding
• Seam welding is a resistance welding process for joining metal sheets in continuous,
seam joints by directly applying opposing forces with electrodes consisting of rotary
wheels
• The current and the heat generation are localized by the peripheral shapes of the
electrodes Wheels.
Application:
▪ Seam welding is mostly applied in manufacturing of contains, radiators and heat
exchangers etc.
❖ Resistance Projection Welding
• Projection welding is a resistance welding process for joining metal component with
Or sheets with embossments by directly applying opposing forces with electrode specially
Designed to fit the shapes of the workpieces.
• The current and the heat generation are localized by the shape of the workpieces either
With their natural shape or with specially designed projection.
• Large deformation or collapse will occur in the projection part of the workpieces implying high
Application:
• Used for mechanical fixing of autobody structure
Ex. Weld nuts
4. What is fusion welding & types of fusion welding with its application in the automotive sector?
Arc welding
• The processes involves either consumable or a non-consumable electrode (rod or wire)
• An arc produced between tip of the electrode and work piece to be welded, by use of an AC
or a DC power supply.
❖ Type of arc welding
1. Manual metal arc welding
2. Gas-shielded metal arc welding (Metal inert gas welding)
3. Gas-shielded tungsten arc welding (Tungsten inert gas welding)
4. Submerged arc welding
5. Plasma arc welding
Manual metal arc welding
• Manual metal arc welding (MMA or MMAW) also known as Shielded metal arc welding
(SMAW), or informally as stick welding
• Stick welding is a process where the arc is struck between the metal rod
(electrode flux coated) and the work piece, the rod and work piece surface melt to create
a weld.
❖ Gas-shielded metal arc welding (Metal inert gas welding)
• Metal inert gas (MIG) welding is an arc welding technique in which
a consumable electrode is used to weld two or more work pieces.
Mig welding makes use of the following components:
➢ Consumable electrode
➢ Inert gas supply
➢ Welding Head
➢ A.C or D.C Power supply
Gas-shielded tungsten arc welding (Tungsten inert gas welding)
• Tungsten inert gas welding (TIG WELDING), also known as gas tungsten arc
welding (GTAW), is an arc welding method that uses a non-consumable tungsten
electrode to weld two or more workpiece.
• it is very much similar to metal inert gas (MIG) welding
• The following components are necessary to per for tungsten inert gas welding.
➢ Power supply
➢ Non-consumable tungsten electrode
➢ Inert gas supply
➢ Filler rod (depend on the nature of work piece
➢ welding head
5.what is the 3-2-1 principle?
• The best and most cost effect method of part location is referred to as the
3-2-1 method
• Minimum: three locator blocks to establish part plane. Three locators or support, are placed
under the work piece
• The three locators are usually positioned on the axial movements downward and 4 radial
movement
• Together the three locators restrict five degrees of freedom.
• Round locating pin in a round hole that defines location in four directions (4-way) perpendicular
to the plane previously established
• This restricts four axial movement
• (1) Round locating pin in a slot that defines two of the directions of the other pin
(2-way) This is restricts two axial movements
6 . Define body coordinate system?
❖ Body coordinate system in BIW
• The body coordinate system has been widely used in the automotive industry for drawing of
body parts. Product and process design
• A coordinate system is a reference system consisting of a set points, Line and surface,
Used to define the position of points in space in either two or three dimensions.
• In general BCS is also called as car line and body line.
• X= longitudinal direction (force & after – f/a) or (Front O Line – FOL)
• Y Transverse direction (Cross car -C/C) or (center O line- CO)
• Z Vertical direction (Up & Down-U/D) or (Bottom O line Bol)
• The origin of the body coordinate system (OX) is defined at the front center of a vehicle.
• It indicates a length of car and the coordinate system (OZ) is below its underbody
indicates height of car, and the coordinate system (OY) its starting point is the center of
car body indicates width of a car
7.Elaborate Body plane system & its essential.
• Body planes are the reference planes in an automotive car. These planes are used to define
the GD & T of all car parts in a automotive domain.
• Body planes are 3 mutually perpendicular imaginary planes. These are generally considered
to be present at the driver position or sometime at the engine location or at the
front end of the car, depending
on the customer
• The measurements from the body planes to the parts are called as bodyline dimensions
❖ These body planes are called as
• FOL Front ‘’O’’ Line
• COL center ‘’O’’ Line• BOL Body ‘’O’’ Line• The measurement along FOL or X axis is called as
F/A Front Aft
• The measurement along COL or Y axis is called as C/C Cross Car
• The measurement along BOL or Z axis is called as U/DUP Down
❖ Bodyline dimensions are essential for the reasons stated below,
• It defines the exact position of each product in the vehicle w. r. t. a fixed origin
• It ensures flawless design for assembly
• While designing lines, all the designs are carried out relative to the bodyline, VIZ.,
Fixtures, turn tables, etc.,
• It assists in easy location of different parts in a vehicle
• It aims in creating a standardized system
• It assists in Quality checks
