Week 2:- BiW Fixture Basics Challenge
1) What is the process of project execution activity?
The project execution activity is the step-by-step procedure to design and manufacture a fixture.
1. RFQ received- Request For Quotation. Here the customer's requirements/specifications are received.
2. 1st Specification discussion meeting- The discussion is done for the date, timeline, technical aspects.
3. Offer submission- The offer is submitted to the customer to check.
4. LOI/PO receipt- after the customer has gone through they will order to proceed.
5. Schedule preparation- The schedule is prepared for the workflow.
6. Manufacturing/BOP ordering- Manufacturing the parts or ordering them from the supplier.
7. Detailing and drawing- The detailed drawing of the product is made according to the customer's need.
8. customer approval- After the drawing is completed the drawing is sent to the customer for approval.
9. design concept preparation- preparation of the method and process for production and design.
10. BOM preparation- After Schedule Preparation, we move on to BOM preparation in which we mention the gearboxes, cylinders that we will require for the project.
11. Mechanical or Electrical assembly- After the parts are acquired the fixture is assembled.
12. Quality inspection- the fixture is inspected for any defects.
13. Internal trial and testing- the fixture is tested before delivering to the customer.
14. Online trials- are performed with all the sensors, sequencing, and controls. It is checked whether everything is being done as per the process. The successful completion of online trials is conveyed to the customer.
15. Packaging- the finished product is packed.
16. Dispatch-The finished fixture is delivered to the customer.
17. Installation as per layout- The fixture is assembled according to the customer's requirement.
18. Trial and training at the customer- The customers are trained on how to handle the fixture.
19. Buy-off meeting- To check for any additional requirements or to check the fixture.
20. Final Handover- The fixture is given to the customer.
2. What are the different joining process?
Spot welding- In this process, the metal sheets are joined together by applying heat and pressure at the spot to be welded.
Resistance projection welding- in this process the force is directly applied to the sheet metal. Here the shape of the part is used for welding.
Resistance seam welding- in this process the sheets are rolled between two rollers, the current is applied between the two rollers.
Arc welding- in this process the electric arc is used to create heat and join two metals. The electric arc is produced by a power source.
MIG welding- metal inert gas welding is a process in which a solid wire is used for welding. the electrode is surrounded by an inert gas.
TIG welding- tungsten inert gas welding. This process is in which a non-consumable tungsten electrode is used.
3. What is resistance welding & its application in the automotive sector?
This is the welding in which the two electrodes are pressed on the sheet metal and the current is applied. Due to the resistance, heat is generated in the metal which welds the metal.
Types of resistance welding
- resistance spot welding
- resistance seam welding
- resistance projection welding
- resistance butt welding
Advantage:
- Similar and dissimilar metals are capable of being welded
- Highly automated
- Efficient with high production rate and high welding rate
- Cost-effective
- Environment-friendly produces little waste or pollution.
- No need for filler metal or extraneous materials such as rods, fluxes, inert gasses, oxygen, or acetylene are required
Disadvantage:
- The thickness of the workpiece is often limited
- It is less efficient for high conductive materials
- High electric power required
- Applications in the automotive industry
- For joining the sheet metal
- cost-effective process.
Applications in the automotive industry
- For joining the sheet metal
- cost-effective process.
4. What is fusion welding & types of fusion welding with their application in the automotive sector?
- In this method, the metal is melted by applying heat. In this, the two metals are melted together at the joining point by heat produced between the two electrodes. Here there is no requirement of external pressure. The filler material may or may not be needed.
- The welding done without the filler material is called autogenous welding.
- The welding done with the filler material, same as the welded metal is called homogenous welding.
- The welding done with the filler material, different from the welded metal is called heterogeneous welding.
Types of fusion welding:
arc welding - Uses electric arc for welding
Laser beam welding- Uses focused laser beam to weld two metals.
Induction welding- Uses electromagnetic induction to heat up the metals.
oxyfuel welding- Uses the combination of oxygen gas and acetyline to weld metal.
solid reactant welding-
Application in Automotive industry
- For joining the body panel and make the BIW.
5. What is the 3-2-1 principle?
- This principle defines the way in which the workpiece is constrained on the fixture.
- The workpiece has 12 DOF
The DOF - Translation: +X, -X, +Y, -Y, +Z, -Z
- Rotational: XCCW, XCW, YCWW, YCW, ZCWW, ZCW
- The first six DOF are fixed by three points. (+Z, -Z, XCCW, XCW, YCCW, YCW)
- Then the next four DOF are by two points perpendicular to the first points. (+X, -X, ZCCW, ZCW)
- Then the next two DOF are fixed by one point perpendicular to all the other points. (+Y, -Y)
6. Define Body coordinate system?
- The body coordinate system lays down the car body in X, Y, and Z directions. It is used for drawing body parts, product, and process design.
- The length of the car is the X-axis. This is called front O line
- The width of the car is the Y-axis. This is called center O line
- The height of the car is the Z-axis This is called the bottom O line
7. Elaborate Body plane system & its essentials?
- The body planes are used for defining the GD&T for the parts. These planes are perpendicular to each other.
Use of body plane
- used for define exact position of each part of the car.
- used for quality inspection
- used for making a standard system
- used for assembly of the car
- used for locating all the parts
