Week 2:- BiW Fixture Basics Challenge

Q.1

Ans. - Following are various steps involved in project activities.

1. RFQ - Request For Quotation

• In this, custmor gives requirements in details for the given project in the form of data.
• also specifies technicsl offer commercial offer etc.

2. First spec Discussion meeting

• After RFQ recieved, all the offers will be discussed
• Also, based on technical offer, commercial offer will finalised.

3. Offer Submission

• After finalization in the meeting, offer will be submitted to customer end.
• Based on technical,cost,quality customer will finalize the offer.

4. LOI/PO Reciept

• After finalize the offer, customer will release the LOI/PO
• Once PO release,we have to start work

5. Schedule Preparation

• Customer will work on preparation of schedule
• It is dividing the different activities like kickoff meeting, design data study,DAP,Quality check etc.

6. BOM Preparation

• Bill of material which is required for project is prepared

7. Design concept preparation

• It include process like load act on panels, clamping process.
• In this, we should conceptualize the basic data like spot plan, cycle time etc.

8. Customer approval

• Also known as Design approval process (DAP)
• After design concept, customer will review its design concept

9. Detailing and drawing release

• Detailing of fixture part which is to be manufactured has been done with giving appropriate dimension.

10. Manufacturing/BOP Ordering

• Mechanical & electrical parts like sensors,cylinders are ordered as per design specification

11. Mechanical / electrical assembly

• After quality check of electrical and mechanical parts, these are assembled

12. Quality Inspection

• After the assembly, again the quality check is done

13. Internal Trial

• After QC, Internal trial are made to check the operation of the fixture

14. Online trial

• The trial will done in automatic made through control panel

15. Packaging

• After approval of QC , packaging is been done as per standards.

16. Despatch

• After packing of fixture, it despatches to customer

17. Installation as per layout

• According to design, the installation team will install the fixture

18. Trails & training at customer

• Production trial will be taken at customer end.

19. Buyoff meeting

• After trials and training at customer end, buyoff meeting will be held

20. Final Handover

• The fixture and document support the fixture will be handed over.

Q.2

Different Joining Processes as follow

A.Metallurgical Joining

It is classified into following

1. Welding

2. Brazing

3. Soldering

* Welding classified into following

a. fusion welding

b. electric resistance welding

c. solid-state welding

2. Brazing

a. Torch brazing

b. furnace brazing

c. induction brazing

d. dip brazing

e. resistance brazing

f. laser brazing

3. Soldering

a. hard soldering

b. soft soldering

c. dip soldering

d. wave soldering

e. resistance and induction soldering

B. Mechanical Joining

1. Self piercing rivet

2. Claucking

3. Hemming and Seamig

4. Bolting

5. Folding

C. Chemical joining

1. Adhesive bonding

Q.3

Resistance welding & its applications

• It is welding technic used for joining sheet metal components
• following are its type

1. Resistance spot welding

This process uses shaped copper - chromium or zinc alloy. Heat is developed mainly at the interface between two sheets.

2. Resistance seam welding

in this, the current & heat generation are localised by the peripheral shapes of electrode wheels

3. Resistance projection welding

As per name, different projections are formed for effective welding.Projection or embossed joints are used for welding purpose.

4. Butt welding

Used to joint component of similar cross section by making a weld across the entire section in a single operation.

5. Precursion welding

It is type of resistance welding that blends dissimilar metals together. it creates high temperature arc that is formed from a short quick electrical discharge.

Application -

• The convensional steel body of car contains 4500 spot weld joints.
• Welding is invariably used in the automotive industries for joining variety of structural components.
• It is used in the form of robotic spot welding in automotive industries to weld the sheet metal.
• Its most common application is in automotive manufacturing industries
• Used in assembly of fuel tank to make it leak proof

Q.4 Fusion welding

In this, the metal at the joint is heated to a molten state and then it is allowd to solidify .Pressure is not applied during welding process . Following are the types of fusion welding.

A. Thermit welding-

welding the parts by using liquid thermit steel around the portion to be welded is called thermit welding.

Advantages -

1.Simple and easy process

2.low setup cost

3.metal joining rate is high

Disadvantages

1.used for limited metal like iron,copper

2.uneconomical for joining light welding parts

B. Arc welding

The process involves either consumable or a non consumable electrode

Following are types of arc welding,

1.Manual metal arc welding

2. MIG welding

3. TIG welding

4. submerged arc welding

5. plasma arc welding

6. atomic hydrogen arc welding

7. carbon arc welding

8. electroslag welding

C. Gas Welding

In this , the edges of metal to be welded are melted by using gasflame . No pressure is applied during welding except pressure gas welding. There are three types of gas welding process.

1.Oxy-acetylene welding

2.Oxy-hydrogen welding

3.Air-acetylene welding

Fusion welding application

• It is used in manufacturing of automobile and construction equipment
• gas welding which is used to weld parts of frame and the chassis.
• manual metal arc welding truck frames and body.
• Used to join different automibile parts.

5. 3-2-1 Principle

A fixture which hold the device to be processed by using 3-2-1 principle

The best and most cost effective method is 3-2-1 principle

3 - minimum locator blocks to establish part plane . three locators are placed under the workpiece. This restricts two axial movement downwards , upward and four radial movements. together, three locators restricts the six degrees of freedom.

2- round locating pin a round hole that defines location in four directions perpendicular to the plane previously established. this restricts four axial movements.

1- round locating pin in a slot that defines two of the direction of other pin . this restricts two radial movements.

hence 3-2-1 principle is defined.

Q.6 Body co-ordinate system

• It has been wildly used in the automotive industries for drawing body parts, products & process design.
  • A co-ordinate system is a reference system consisting of set of points , line used to define position of points in space in either two or three dimension
• X- Longitudinal direction
• Y- Transverse direction
• Z- vertical direction
• The origin of the body coordinate system (OX) is defined at the front centre of the vehicle.
• The co-ordinate system OZ below its underbody indicates highest of the car
• The co-ordinate system OY its starting point is the centre of the car body indicate the width of the car
• The origin will be differ from car makers to car makers

Q.7 Body Plane system

• Body planes are the reference plane in automotive car. These planes are used to define the GD&T of car part.
• The measurements from body plane to the parts are called body line dimensions.
• So these body parts called as

a. FOL - Front O line

b. COL - Centre O Line

c. BOL - Body O Line

d. The measurement along FOL or X axis is called as F/A or front Aft

e. The measurement along COL or Y axis is called as C/C or Cross car

f. The measurement ALong BOL or Z axis is called as U/D or Updown

Essentials of body plane

Body line dimensions are essential for the reason stated below,

1. It defines the exact position of each product in the vehicle with respect to a fixed origin.

2. It ensures the flawless design for assembly.

3. while designing line ,all the designe are carried out relative to the body line.

4. It assist in easy location of different parts in a vehicle.

5. It aims in creating a standardized system

6. It assist in quality check.