Week 2:- BiW Fixture Basics Challenge

1. What is the process of project execution activity?

Hers is the process of project activity

2.What are the types of joining processes?

• To get any structural large parts for quality and designed we use joining process.

• In this process whole structure can be into a one part.

Basically we classified two types of joining process;

MECHANICAL joining process.

METALLURGICAL joining process.

In mechanical joining process we divided into two groups;

• With fasteners(screws,bolts and nuts)

• Without fasteners(riveting,caulking,shrink fitting,)

Advantages of mechanical joining process;

• No thermal structural transformation in work pieces.

• High strength and rigid in work pieces.

• good quality and appearance in work pieces.

• Mobility of material after joining.

In metallurgical welding there are different types;

• WELDING.

• BRAZING .

• SOLDERING.

ADAVNTAGES of metallurgical process;

• The joints should be permanent in work piceces.

• Less time consumptionin work.

• Easy to be work in work location.

WELDING are classified into variuos types ;

• RESISTANCE WELDING(SPOT,SEAM,PROJECTION)

• ARC WELDING(MIG,TIG,PLASMA,FLUXED CORE)

• GAS WELDING (OXY-ACETLYENE,OXT-HYDROGEN,AIR ACETYELNE,PRESSURE GASS)

• THERMO CHEMICAL WELDINGTHERMIT,ATOMIC HYDROGEN)

• RADIANT ENERGY WELDING(ELECTO BEAM,LASER BEAM)

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

• Resistance welding is the process widely used in manufacturing industry to joining th sheet metals components

• In resistance welding the weld is made by conducting the current through the metal to heat the material and melt the material at localised point.

• in the process we use electrodes inbetween the material to weld.

Mojarly there are three types of resistance welding;

• RESISTANCE SEAM WELDING.
• RESISTANCE SPOT WELDING.
• RESISTANCE PROJECTION WELDING.

RESISTANCE SEAM WELDING.

• Seam welding is the process for joining the metal sheets in leak tight.

• sweam joints are directlyapply the force by using electrodes with the shape of rotary wheels.

• Current and heat generation are localized in pheripheral shape of electrode wheels.

Applications of seam welding;

• It is mostly used to make containers.tanks,radiators and heat exchangers etc.,

RESISTANCE SPOT WELDING;

• Resistance spot welding is th eprocess for joining sheet metals by using copper chromiummir zirconium alloy lectrodes to apply pressure on sheet meral and convet the elcetrical current throught work piece
• In spot welding heat is developed mainly inteface between 2 sheet metalsand it is to be welded and lok like molten pool
• the molten pool contains the pressure applied from elcteode tip and solid sheet metal.

Application of spot welding;

• Welding time is low .
• Highly recommended for automation industry robotic process.
• strenght and durability is high but it depends on quality of resistance spot welding.
• 

RESISTANCE PROJECTION WELDING;

• Resistance projection welding is the porcess to joining sheet matals with embossed electrodeand alos directly appluing the force to work piece .
• The electrode is specially made for profile of work pieces.
• The heat and current generation are localized to thw work piece or specially designed projection surface.
• If deformation or collapse occurs it damage the projection part of work piece.

Applications;

• It mainly use dto weld the nuts in sheet metals
• To joining the body parts by using mechanical joint we use this to weld nuts.

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

• Fusion welding is the process in which faying parent surfacwe,as well as filler material,during welding the weld line will be formed.

• In this process the work pieces will get based on process.

• Outside pressure is not needed like resistance welding process.

• In fusion welding the filler material will be added in work pieces.

TYPES OF FUSION WELDING;

• ARC WELDING.

• RESISTANCE WELDING.

• GAS WELDING.

• HIGH ENERGY WELDING.

ARC WELDING they are different types;

• MANUAL METAL ARC WELDING.

• GAS SHIELDED MATAL ARC WELDING(MIG).

• GAS SHIELDED TUNGSTEN ARC WELDING(TIG).

• SUBMERGED WELDING.

• PLASMA ARC WELDING

TYPES OF RESISTANCE WELDING;

• SEAM WELDING.

• SPOT WELDING.

• PROJECTION WELDING.

TYPES OF GAS WELDING;

• OXY FUEL WELDING.

TYPES OF HIGH ENERGY WELDING;

• HIGH BEAM WELDING.

• LASER BEAM WELDING.

APPLICATION OF FUSION WELDING;

• Fusion welding process is the process widely used to assembly one or more parts in automotive sector.

• In all joining process of automobiles we use 90%welding process only.

• It is easy to work and fast working.

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

• 3-2-1 Principle is the most effective and better costing methods of part locating in fixtures.

• By using 3-2-1 principle we arrest all 12 degrees of freedom in workpiece to locate the fixture.

• 3 referas to three locating blocks.

• 2 refers to two locating round pins.

• 1 refers to one locationg round pin in slot.

• Three locating blocks are used to arrest five degrees of freedom ,thats in four radial movement(clockwise and anticlock wise rotationof X,Y axis) and one axial movement that is downward movement

• Two round locating pins are usd to arrest the four axial movement (X+,X-,Y+,Y-)

• One round locating pin in slot are used to arrest the two axial movement(Z+,Z-)

6.Define Body coordinate system?

• The body co ordinate system is widely used in the automotive for parts of car,product and process design

• The coordinate system is the reference system that consist of set point,lines and surfaces

• It used todefine the reference points in drawing when two or more dimensions in one drawing

in this system three axis are indicates three directions of car

X = LONGITUDINAL DIRECTION is also known as FRONT O LINE(FOL)

Y = TRANSVERSE DIRECTION is also known as CENTRE O LINE(COL)

Z= VERTICAL DIRECTION is also known as BOTTOM O LINE (BOL)

The origin point in this co ordinate system we indicates

OX is FRONT CENTRE OF CAR nad indicates LENGTH OF THE CAR

OY is starting point is CENTRE OF THE CAR BODY and indicates WIDTH OF THE CAR

OZ is UNDER BODY OF CAR and indicates HEIGHT OF THE CAR

7.Elaborate Body plane system & its essentials.

Body planes are the reference plane in the automative car.it is used to defines the GD&T of all car parts in automotive domain.

Body planes are consider as a 3 perpendicular imaginary palnes

These planes are consider as a driver position or engine location or front end of the car depends on requirements.

the 3 planes are;

FRONT O LINE(FOL)

CENTRE O LINE (COL)

BODY O LINE (BOL)

THE MEASUREMENT OF FOL (XAXIS) IS CALLED AS F/AFRONT AFT

THE MEASUREMENT OF COL(YAXIS) IS CALLED AS CC CROSS CAR

THE MEASUREMENT OF BOL(ZAXIS) IS CALLED U/D UP DOWN

ESSENTIALS OF BODY PLANE DIMENSIONS;

• It deifne the exact parts and position of the vehicl with respect to fixed origin.

• it helps to ensure no errors in design and assembly.

• It helps to assit the locating the different vehicle parts by using these planes.

• It helps to check the dimensions and coordinates of vehicles and fixtures.

• In design all the dimension are carried through the body plane origin point and also in fixtures too.