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Week 2:- BiW Fixture Basics Challenge
BIW FIXTURE BASICS CHALLENGE 1.What is the process of project execution activity? There are two types of industries. Line Builders - Design and manufacture with in our industry. Design Service Industries - Design and give it to a manufacuring industry. Line Builders RFQ-Request for quotation: The part that is to be…
Bharath P
updated on 21 Jan 2023
BIW FIXTURE BASICS CHALLENGE
1.What is the process of project execution activity?
There are two types of industries.
- Line Builders - Design and manufacture with in our industry.
- Design Service Industries - Design and give it to a manufacuring industry.
Line Builders
RFQ-Request for quotation:
The part that is to be manufactured is requested from the customer side.
First Spec Discussion Meeting:
The meeting held to discuss whether the product should be designed and manufactured.
Offer Submission:
The discussions (wheather there is any changes) held in the meeting is conveyed to the customer .
LOI/ PO Receipt:
The PO is generated by the customer to design and manufacture the product.
Shedule Preparation:
The Process is sheduled as per each department (time limit are alloted fro each department).
BOM Preparation:
The Bill of materials is prepared as per the product(List of the raw materials, sub-assemblies, intermediate assemblies, sub-components, parts, and the quantities of each needed to manufacture an end product).
Design Concept:
The design concept is made with respect to the product.
A design concept is the core idea driving the design of a product, explained via a collection of sketches, images, and a written statement. This helps the designers and, later, the developers stay on track throughout the creative process, ensuring they bring a product to market with value to target users.
Customer Approval:
The design concepts are submitted to the customer for approval.
Detailing /Drawing Release:
Once the customer approves the drawing it is released for manufacuring process.
Manufacturing / BOP Ordering:
The required materials are ordered and manufacuring process should be started.
Mech / Elec assembly:
Once the product passes all the quality inspections it is taken to the assembly of Mechanical and electrical parts.
Quality Inspection:
After the assembly the quality inspection takes place on the product.
Internal Trial Testing:
The trial products are manufactured and subjected to inspections.The ispections are taken place after the final assembly.
Online Trial:
These trials are taken place in the mode of electrical means.
Packaging:
Once the trial are approved by the customer side then we can pack these products with packing standard to avoid damages.
Dispatch:
The product is dispatched to the customer end.
Installation As Per Layout:
The fixtures are installed as per the layout given on the customer end.
Trials and Training at customer:
Trials are taken at the customer end and training should be given .
Buy off Meeting:
Finally, if any further changes in the product is discussed .
Final Handover:
If there is no changes to be made the project should be handed over to customer.
Design Service Industries
The data that has to be designed is given as a input .
We have to study the design whether it should be manufacturable.
Developing the 3D concept design of the given product.
Analyse it with the simulation analysis.
If it does not passes then we have to update the design .
If it passes then we can go for Quality check (Both dimension and visuals).
After the quality inspection the product is sent for customer review.
If it does not passes the quality inspection and customer review then we have to update the design in every aspect.
Once the customer approves that ,then we go for 2D detailing (Providing proper dimensions and tolerances)
The 2D detailing is subjected to Quality check.
If it does not passes the quality check then we have to edit the 2D detailing.
Then the data is delivered to the customer.
2.What are the types of joining processes?
The durability and performance of any structure is largely dependent on the quality and the design of the component joints.
Whole structure cannot be made in one piece.
Two fundamental options for joining materials and components.
1)Mechanical Joining:
A mechanical joint is a section of a machine which is used to connect one or more mechanical part to another.
Mechanical joints may be temporary or permanent, most types are designed to be disassembled.
Most mechanical joints are designed to allow relative movement of these mechanical parts of the machine in one degree of freedom, and restrict movement in one or more others.
Types:
Mechanical Fastening
Joining of prepainted steels or dissimlar metals.
Material Require high fatigue life compared to static life.
Material have long tool life. Screws and bolts are used here.
Self Piercing Riveting
High speed mechanical fastening method for point joining sheet metal(Steel and aluminium).
Semi tubular rivets and solid rivets are used.
Predrilled holes are not required (Rapid Operation).
Hemming
Hemming or seaming are two similar metal working process in which the sheet metal edge is rolled over on itself.
Hemming - edge roll to itself
Seaming- Two material edges are joined.
Adhesive Bonding
It is used to fasten two surfaces together, usually produces a smooth bond.
The joining technique involves glues , epoxiesor various plastic agents that bond by evaporation of a solvent or by curing a bonding agent with heat , pressure or time.
2)Metallurgical Joining:
Metallurgical joining includes fusion welding, pressure welding and brazing/soldering which use different energies.
Every joining method has advantages and disadvantages.
To ensure efficient joining, you need to select the right method according to the materials and joining conditions.
Types:
Resistance Welding
It is a 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 predetermined by the design of the electrodes and or the workpieces 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 forge the workpieces.
Types of Resistance Welding
- Resistance Spot Welding
- Resistance Seam Welding
- Resistance Projection Welding
Fusion Welding
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.
Types of Fusion Welding
- Arc Welding
- Induction Welding
- Oxyfuel welding
- Laser Welding
- Solid Reactant
Pressure Welding
Pressure welding is a process in which external pressure is applied to produce welded joints either at temperatures below the melting point, which is solid state welding, or at a temperature above the melting point, which is fusion state welding.
Types Of Pressure Welding
- Diffusion Welding
- Friction Welding
- Ultrasonic Welding
- Cold Pressure Welding
- Forge Welding
- Explosion Welding
Brazing or Soldering
Both soldering and brazing are metal joining processes used to join two similar or dissimilar metals but in different joining conditions.
Brazing is a welding technique used to join two pieces of metal together using a metallic filler that has been melted and flowed into the joint.
Types of Brazing and Soldering:
- Torch Brazing
- Induction Brazing
- Resistance Brazing
- Furnance Brazing
- Dip Brazing
3.What is Resistance Welding & its application in the automotive sector?
This technology is widely used in manufacturing industry for joining metal sheet and components.
The weld is made by conducting a strong current through the metal combination to heatup and finally melt the metals at localized points predetermined by the design of the electrodes and the work pieces to be welded.
A force is always applied before , during and after the application of current to confine the contact area of the weld interfaces and in some applications , to forge the work pieces.
TYPES OF RESISTANCE WELDING:
RESISTANCE SPOT WELDING:
The process is used for joining sheet materials and uses shaped copper-chromium and 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 elecrode tip and the surrounding solid metal.
Shot weld time and hence high weld speed .
Highly adoptable to automation and robotic techniques.
Typically BIW contains 5000 welds .
Strength and durability of automobile largely depends on quality of resistance spot welding.
RESISTANCE PROJECTION WELDING:
It is a resistance welding process for joining metal components or sheets with embossments directly applying opposing forces with electrodes specially designed to fit the shapes of the workpieces.
The current and the heat generation are localised by the shape of the workpiece 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.
RESITANCE SEAM WELDIND:
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 pheripheral shape of the electrode wheels.
FLASH BUTT WELDING
It is another type of resistance welding which is used to weld tubes and rods in steel industries.
In this process, two work pieces which are to be welded will be clamped in the electrode holders and a high pulsed current in the range of 100000 ampere is supplied to the work piece material.
In this two electrode holders are used in which one is fixed and other is movable.
Initially the current is supplied and movable clamp is forced against the fixed clamp due to contact of these two work pieces at high current, flash will be produced.
When the interface surface comes into plastic form, the current is stopped and axial pressure is increased to make joint. In this process weld is formed due to plastic deformation.
APPLICATIONS
- Resistance welding is widely used in automotive industries.
- Projection welding is widely used in production of nut and bolt.
- Seam welding is used to produce leak prove joint required in small tanks, boilers etc.
- Flash welding is used to welding pipes and tubes.
4.What is fusion welding & types of fusion welding with its application in the automotive sector?
Definition
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.
TYPES OF FUSION WELDING:
- Arc welding
- Laser welding
- Induction Welding
- Oxyfuel welding
- Solid Reactant
ARC WELDING:
The process involves either consumable or a non consumable electrode (Rod or Wire).
An arc produced between tip of the electrode and workpiece to be welded , by use of an AC or a DC power supply.
TYPES OF ARC WELDING:
1.MANUAL METAL ARC WELDING:
Manual metal arc welding (MMA /MMAW) also known as sheilded 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 workpiece , both the rod and workpiece surface melt to create a weld.
2.GAS SHEILDED METAL ARC WELDING (Metal Inert Gas /MIG welding)
It is an arc welding technique in which a consumable electrode is used to weld two or more workpieces .
MIG makes use of the followig components ,
- Consumable Electrode
- Inert gas suppy
- Welding head
- AC or DC power supply
3.GAS SHEILDED TUNGSTEN ARC WELDING(Tungsten Inert Gas /TIG welding)
This method uses non consumable tungsten electrode to weld two or more work pieces.
It is very much similar to metal inert gas /MIG welding.
Components that are required to perform TIG are ,
- Power Supply
- Non consumable tungsten electrode
- Inert gas supply
- Filler Rod (Depends on the nature of the workpiece)
- Welding head
4.SUBMERGEED ARC WELDING
SAW works with a granular flux that creates a thick layer during welding, which completely covers the molten metal and prevents sparks and spatter.
This method enables deeper heat penetration because it acts like a thermal insulator. SAW is used for high-speed sheet or plate steel welding.
It can be semiautomatic or automatic. However, it is limited to horizontal welds.
5.PLASMA ARC WELDING
This arc welding technique uses ionized gases and electrodes that create hot plasma jets aimed at the welding area.
As the jets are extremely hot, this method is for narrow and deep welds. PAW is also good for increasing welding speeds.
LASER WELDING:
Another type of fusion welding is laser welding. Also known as laser welding, it involves the use of light radiation to produce heat.
The laser welding rig essentially blasts the surfaces with radiated light. With each blast, the surfaces become a little hotter. As the objects melt, they fuse together.
INDUCTION WELDING
In addition to arc and laser welding, there’s the fusion welding process known as induction welding.
Induction welding is distinguished from all other types of fusion welding because it’s the only one in which there’s no direct contact between an object’s surface and the heat source.
With induction welding, a wrapped coil is used to create a magnetic field that heats metal.
The magnetic field quickly heats the metal, causing to melt and fuse together.
OXYFUEL WELDING:
A type of chemical-based fusion welding, oxyfuel welding involves the use of a flame to heat and join surfaces, with oxygen as the fuel source.
Fire, of course, needs oxygen, which is the basis on which oxyfuel welding works.
The oxygen fuels the fire to create a hot flame in excess of 4,500 degrees Fahrenheit.
Oxyfuel welding typically uses a combination of oxygen and a flammable gas to create a hot flame to join objects.
SOLID REACTANT WELDING
Solid reactant welding is a type of fusion welding that relies on chemical reactions with certain materials to join them.
There are compounds, for instance, that create heat when mixed together. Solid reactant welding uses this principle to join two or more objects.
5.What is the 3-2-1 principle?
A fundamental concern in metalworking is locating the part to be machined, punched, bent, or stamped relative to the work platform (fixture).
For example, a CNC machine tool starts its process at a specific point relative to the fixture and proceeds from there.
Hence, the accuracy with which a part is machined is quite dependent on the accuracy with which it is positioned in the fixture.
Accurate locating of not just one part, but each and every part that is loaded into the fixture is crucial.
Any variation in part location on the fixture adds to the dimensional tolerance that must be assigned to the finished parts.
Additionally, the method of supporting and securing the part in the fixture affects not only dimensional tolerances, but surface finishes as well.
This is true because improper supporting or clamping can temporarily or permanently deform the part.
Hence, techniques for supporting and clamping must be considered together with the method of locating in order to assure repeatability from part-to-part.
Locating of a part to be machined is a three-step process:
1. Supporting
2. Locating (positioning)
3. Holding (clamping)
The Locating Process: Degrees of Freedom
In order to completely specify the position in space of a three-dimensional
object, we refer to six coordinates:
- Translational position along the X-axis
- Translational position along the Y-axis
- Translational position along the Z-axis
- Rotational position about the X-axis
- Rotational position about the Y-axis
- Rotational position about the Z-axis
These six coordinates are known as the six degrees of freedom of a three-dimensional object.
As the double-headed arrows indicate, the translational and rotational positions can vary in either direction with respect to each of the three axes.
To completely prevent movement, all six degrees of freedom must be restricted.
We have two objectives when mounting a part in a fixture for machining:
1. Accurately position the part at the desired coordinates.
2. Restrict all six degrees of freedom so that the part cannot move.
A widely used method of accomplishing these two objectives uses the 3-2-1 principle, so-called because it entails three steps that employ three, then two, then one fixed points of known location.
Since that adds up to six fixed points, it’s also known as the six point method.
In the three steps of the 3-2-1 method, three mutually perpendicular planes, called datum planes, are introduced, one at each step.
These three planes define the workpiece position, and together with opposing clamping forces fully constrain the part.
Three locator blocks to establish part plane.
Three locators, or supports are placed under the workpiece .
The three locators are usually positioned on the primary locating surface.
This restricts one axial movement downward and four radial movements.
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 establised.
This restricts four axial movements.
Round locating pin in a slot that defines two of the directions of the other pin (2-way). This restricts two axial movements.
6.Define Body coordinate system?
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 of a set of points , lines and surfaces used to define the positions of points in space in either two or three dimensions.
In general BCS is also called as car line and body line .
The origin of the coordinate system (OX) is defined as the front centre of a vehicle, it indicates a length of car and the coordinate coordinate system (OZ) is below its underbody indicates the height of the car, and the coordinate system (OY) is stating point is the centre of car body indicates width of the car.
To represent the position of biw car parts,welding fixture and its unit assemblies with its individual parts (e.g. mylars(the parts which are in contact with panel)) in 2D drawings, their respective positions are shown with reference to (X=0,Y=0,Z=0)positions.
In short it shows in 2D XY, YZ or XZ coordinate position of BIW welding fixture parts or assemblies with reference to origin X=0,Y=0,Z=0
Let us consider a situation if individual fixture designer starts designing a part or panel on their default axes system then it will be difficult to assembly or position the part with respect to each other.
So in order to avoid this all the designer starts designing with respect to car axes system (which is generally at center of front axle)
7.Elaborate Body plane system & its essentials.
These are reference planes in an automotive car.
These are used to define the GD & T of all car parts in an automotive domain.
Body planes are three mutually perpendicular imaginary planes.
These are generally considered to be present at the driver position or sometimes at the engine location or at the front end of the car depending on the customer.
The measurements from the bod planes to the parts are called as bodyline dimensions.
The bodyplanes are also called as
FOL - Front O Line
COL - Centre O Line
BOL - Body O Line
FOL or X Axis - F/A Front Aft
COL or Y Axis - C/C Cross car
BOL or Z axis - U/D Up Down
Bodyline dimensions are essential for the reasons stated below-
- Exact position of each product in the vehicle with respect to a fixed origin.
- Ensure flawless design for assembly
- While designing lines , all the designs are carried out relative to the bodyline . Eg- Fixtures, Turntable etc.
- It assists in easy location of different parts in a vehicle.
- It aims in creating a standardized system.
- It Assists in quality checks.
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