Week 2:- BiW Fixture Basics Challenge

Week 2: - BiW Fixture Basics Challenge

Q1. What is the process of project execution activity?

Ans.

Various processes in the project execution activity:

• RFQ received – It is the initial stage in project activity where the quotation for the required component is received from a customer by the concerned department of the organization. RFQ stands for Request FOR Quote.
• 1st spec discussion & offer submission – After receiving the RFQ, the technical team schedules the initial meeting with the technical head and gathers all the technical data and gathers all the technical and study them carefully.
• Offer Submission: Once the meeting is done a technical offer for the required part is submitted in the documentation that has all the details of the technical details like weldings spots, type of welding, material grade, etc
• LOI/PO Receipt - Once the clarification is done from the customer end, they send a purchase offer (PO) to the company for design preparation and production.
• Schedule preparation - Once the company receives PO, the technical team and production team schedules preparation for development like Cycle time, Production plan study, etc.
• BOM preparation - Bill of material is prepared for the project like the BO parts, grippers, cylinders, motors etc. which are required.
• Design concept preparation - The customer gives data or the specifications for the design. Based on that data design process is start which fulfills all the customer requirements.
• Customer approval - After designing the concept the approval of the customer is required. Customer checks the design fulfills the requirements or not according to the technical offer. If yes the customer gives approval for the design or customer will also ask for some addition or the changes in the design. By doing the necessary changes final approval is taken from the customer.
• Detailing & DWG release - After the approval from customer DWG are released whic shows the detailed specifications of all the parts required. Like dimensions, Qty, Specifications etc.
• Manufacturing BOP ordering - The BO parts like motors, cylinders, sensors, gripper etc. required for manufacturing are ordered as per the design specifications.
• Mechanical/ Electrical assembly- Once the parts are received they goes for the prior Quality control checking. In this all the parts are checked as per the specification. After QC checking the Mechanical or electrical assemblis are prepared as per the design.
• Quality inspection - After the assembly again the quality is checked. In this all the dimensions, positional accuracy, Coordinates are checked by using CMM machine.
• Internal trial & testing & online trial - After the QC check internal trials are taken to check the fixture can do the operation or not for what it is designed. The simulation is done for this purpose at early stage. In this the fixture is checked for the clamping of the part, welding ,proper loading & unloading of the part etc.
• After this online trial is taken in which all the operations done in automated mode by using electrical connections. The process sequence is checked as per the defined way in design in automated mode. Customer is also involved in online trial for taking the approval.
• Packaging & dispatch - The assemblies are packed in proper manner. Because in transportation the fixture will be damaged hence it distorts the geometry of the fixture & also the functionality of the fixture. Hence the proper packaging is very important. Once the packaging is done the fixture is dispatched to the customer address.
• Installation as per layout - Layout is the space defined for the parts like fixture, robots etc, according to the functionality, application, process sequence etc. The layout is done at very initial level & according to that installation is done.
• Trials & training at customer - Production trials are taken at customers end. In technical offer we have specified the quality benchmarks for the fixture, the capability of the fixture for production etc. The trials are taken to check the capability of the fixture. Once it is done then training is given to the operator, staff & engineer for the process sequence, how the fixture works, loading & unloading of the part etc.
• Buy off meeting & Final handover - After trials and training work is done a buy-off meeting is set with the customer to establish a good business with the vendor. Final Handover is the final step to hand over all related documents with the product to the customer.

Q2. What are the types of joining processes?

Ans. Durability and performance of any structure is largely dependent on the quality and the design of the component joints.

Different types of joining processes are

• Metallurgical joining process
• Mechanical joining process

Resistance Welding: Resistance welding is a welding technology widely used in manufacturing industry for joining metal sheets and components.

Weld is made by conducting a strong piece of current through the metal combination heat up and finally melt the metal at localized points predetermined by the design of 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 application, to forge workpiece.

Types of Resistance welding:

• Resistance spot welding
• Resistance seam welding
• Resistance projection welding

Resistance spot welding: This process is used for joining sheet materials and uses shaped copper chromium or zirconium alloy electrodes to apply pressure and convey the electrical current through the workpiece

Heat is developed at the interface between two sheets, eventually causing the material being welded to melt, forming a molten pool, the weld nugget

Resistance projection welding: This process is used for joining sheet materials and uses shaped copper-chromium or zirconium alloy electrodes 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.

Seam welding is a resistance welding process for joining metal sheets in continuous, often leak tight, 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 electrode wheels.

Manual metal Arc welding: Manual metal arc welding (MMA or MMAW known as Shielded metal are 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, both the rod and work piece surface melt to create a weld

Gas-shielded metal arc 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.

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

• Manual metal arc welding
• Gas-shielded metal arc welding (Metal inert gas (MIG) welding)
• Gas-shielded tungsten arc welding (Tungsten inert gas (TIG) welding)
• Submerged arc welding
• Plasma Arc Welding

Mechanical fastening: The joining of material combinations which cannot be easily welded such as pre-painted steels or very dissimilar metals

Ex : Al application in auto body make use of mechanical fastening techniques to overcome the poor inherent weld ability of Al The joining of materials in applications where high fatigue life is critical compared to static strength

The joining of materials where a long tool life is of relative importance

Self-piercing riveting: Self-piercing riveting is a high-speed mechanical fastening process for point joining sheet material, typically steels and aluminium alloys it is a single-step technique, generally using a semi-tubular rivet to clinch the sheets in a mechanical joint. There is also a process variant which utilises solid rivets.

As the name suggests, pre-drilled holes are not required allowing the joint to be made rapidly in one operation The process cycle is shown in cross-section

Hemming process: Hemming and seaming are two sim working processes in which a sheet metal is rolled over onto itself

Hemming is the process in which the edge is rolled flush to itself, while a seam joins the edges of two materials.

Adhesive Bonding: Adhesive bonding is used to fasten two surfaces together, usually producing a smooth bond.

This joining technique involves glues, epoxies, or various plastic agents that bond by evaporation of a solvent or by curing a bonding agent with heal, pressure, or time

Q3. What is Resistance Welding & its application in the automotive sector?

Ans. Resistance Welding: Resistance welding is a welding technology widely used in manufacturing industry for joining metal sheets and components.

Weld is made by conducting a strong piece of current through the metal combination heat up and finally melt the metal at localized points predetermined by the design of 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 application, to forge workpiece.

Types of Resistance welding:

 Resistance spot welding

 Resistance seam welding

 Resistance projection welding

Resistance spot welding: This process is used for joining sheet materials and uses shaped copper chromium or zirconium alloy electrodes to apply pressure and convey the electrical current through the workpiece.

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

Resistance spot weld section

Advantage:

• Short weld time and hence high weld speed
• Highly adaptable to automation and robotic techniques. Typical B/W contains 5000 welds
• Strength and durability of automobile largely depends

Resistance Projection Welding

Projection welding is a swing process for joining metal components or sheets with embossments by directly applying opposing forces with electrodes 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 structures eg Weld nut

Resistance seam welding:

Seam welding is a resistance welding process for joining metal sheets in continuous, often leak tight, 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 electrode wheels.

Application:

Seam welding is mostly applied in manufacturing of containers, radiators and heat exchangers

Q4. What is fusion welding & types of fusion welding with its application in the automotive sector?

Ans. Fusion welding is a process that uses heat to join or fuse two or more materials by heating them to melting point. The process may or may not require the use a filler material. External application of pressure is not required for fusion welding processes, except for resistance welding, where substantial contact pressure is required during welding for sound joining.

Arc welding is a type of welding process using an electric arc to create heat to melt and join metals. A power supply creates an electric arc between a consumable or non-consumable electrode and the base material using either direct (DC) or alternating (AC) currents.

The processes involves either consumable or a non-consumable electrode (rod or wire)

Type of arc welding

• Manual metal arc welding
• Gas-shielded metal arc welding (Metal inert gas (MIG) welding)
• Gas-shielded tungsten arc welding (Tungsten inert gas (TIG) welding)
• Submerged arc welding
• Plasma Arc Welding

Manual arc welding: Manual metal arc welding (MMA or MMAW), also known as shielded metal arc welding (SMAW), flux shielded arc welding or stick welding, is a process where the arc is struck between an electrode flux coated metal rod and the work piece. Both the rod and the surface of the work piece melt to create a weld. MMA welding can be used to join most steels, stainless steels, cast irons and many non-ferrous materials.

Gas Shielded Metal Arc Welding: MIG welding is an arc welding process in which a continuous solid wire electrode is fed through a welding gun and into the weld pool, joining the two base materials together. A shielding gas is also sent through the welding gun and protects the weld pool from contamination.

Gas Tungsten Arc Welding or Tungsten Inert Gas Welding (GTAW or TIG): It is the most common type of fusion welding used in the automotive industry. It uses non-consumable tungsten electrodes to melt the metal parts thus releasing inert gases like Argon(Ar) or Helium(He) when AC or DC is supplied to the system. It works under very high temperatures compared to other welding processes. eg: Aluminium components of cars, etc.

Submerged-arc welding (SAW): Submerged Metal Arc Welding is a common arc welding process that involves the formation of an arc between a continuously fed electrode and the workpiece. A blanket of powdered flux generates a protective gas shield and a slag (and may also be used to add alloying elements to the weld pool) which protects the weld zone.

Plasma arc welding (PAW): Plasma Arc Welding is an arc welding process very similar to TIG welding as the arc is formed between a pointed tungsten electrode and the workpiece. However, by positioning the electrode within the body of the torch, the plasma arc can be separated from the shielding gas envelope. Plasma is then forced through a fine-bore copper nozzle which constricts the arc.

Q5. What is the 3-2-1 principle?

Ans. 3-2-1 PRINCIPLE

The best and most cost effective method of part location is referred to as the 3-2-1 method.

(3.) Minimum: three locator blocks to establish part plane. Three locators, or supports, are placed under the work piece. The three locators are usually positioned on the primary locating surface. This restricts one axial movement downward, and 4 radial movements. Together, the three locators restrict five degrees of freedom.

(2.) 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 restricts two axial movements.

Q6. Define Body coordinate system?

Ans. 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 of points ins and used to define the positions of points in space in either two or three dimensions.

X-X: This is the X-axis or Longitudinal axis of a Car body along the length of the car. This is also known as front O Line (FOL).

Y-Y: This is the Y-axis or Transverse axis of a car body which is along the width of the car. This is also known as Center O Line (COL).

Z-Z: This is the Z-axis or Vertical axis of a car body which is along with the height of a car. This is also known as Body O Line (BOL).

Q7. Elaborate Body plane system & its essentials.

Ans. Body planes are three mutually perpendicular imaginary planes. These are reference planes in automotive car. These are used to define GD & T of all parts in automotive domain.

The measurement from body plane to parts are called body plane dimensions.

A coordinate system is a reference system consisting of a set of points ins and used to define the positions of points in space in either two or three dimensions.

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