Week 2:- BiW Fixture Basics Challenge

1. What is the process of project execution activity?

Ans:

1. RFQ recieved
2. Discussion meeting
3. Offer submission
4. LOI/PO reciept
5. Schedule preparation
6. BOM preparation
7. Design concept validation
8. Customer approval
9. Detailling and Dwg release
10. Manufacturing/BOP odering
11. Mech/Electrical assembly
12. Quality inspection
13. Internal trail and testing
14. Online trail
15. Packaging
16. Dispatch
17. Installation as per layout
18. Trails and training at customernc
19. Buy off meeting
20. Final hardware

2. What are the types of joining processes?

Ans:

• Resistance welding
• Resistance projection welding
• Resistance spor welding
• Resistance seam welding
• Arc welding
• Manual metal arc welding
• Gas sheilded metal arc welding
• Gas sheilded tungsten arc welding
• Mechanical fastening

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

Ans:

• It is widely used method for joining metal sheets and components.
• The weld is made through the metal combination to heat up and finally melt the metals at localized point(s) 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 workpieces.
• Types of resistance welding:

1. Resistance spot welding

2. Resistance seam welding

3. Resistance projection welding

4. 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.

Types of fusion welding:

1. Manual metal arc welding:

• Manual metal arc welding also known as stick welding.
• stick welding is a process where the arc is struck between the metal rod and the workpiece,both the rod and work piece surface melt to create a weld.

2. Gas shielded metal arc welding or metal inert gas welding :

• Metal inert gas welding is arc welding technique in which a consumble electrode is used to weld weld two or more workpieces.

MIG welding makes use of the following components:

• Consumble electrode
• Insert gas supply
• welding head
• A.C or D.C Power supply

3. Gas sheilded tungsten arc welding:

• Tungsten inert gas welding is an arc welding method that uses a non-consumble tungsten electrode to weld two or more workpieces.It is very much similar to metal inert gas welding.
• The following components are necessary to preffer tungsten inert gas welding:

1. Power supply
2. Non-consumble tungsten eletrode
3. inert gas supply
4. Filler rod
5. welding head

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

Ans:

• The best and most cost effective method of part location is reffered to as the 3-2-1 method.
• Minimum:three locators blocks to establish part plane.Three locators , or supports ,are placed under the workpiece.The three locators are usually positioned on the primary locating surafce.This restricts one axial movement downward, and 4 radial movements.Together,the three locators restrict five degrees of freedom.
• Round locating pin in a round hole that defines locations in four directions (4-way) perpendicular to the plane previously established.This restricts four axial monement.
• 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?

Ans:

The body coordinate system has been wdely 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,lines , and surfaces used to define the positions of points in space in either two or three dimensions.

In general the BCS is also called as car line and body line.

7. Elaborate Body plane system & its essentials

Ans:

• Body planes are the refernce planes in an automotive car. These planes are used to define the GD and T of all car parts in a automotive domain.
• Body planes are 3 mutually perpendicular imaginary planes. These arev generally considered to be present at the driver position or something st the engine location or the front end of the car,depending on the customer
• The measurements from the body planes to the parts are called as bodyline dimensions.

Bodyline dimensions are essential for the reasons stated below:

• It defines the exact position of each product in the vehicle with respect to a fixed origin
• It ensures flawless design for assembly
• while designing lines all the designs are carried out relative to the bodyline with respect to fixtures,turn tables etc
• It attains in easy location of different parts ina vehicle
• It assists in quality checks.