Week 2:- BiW Fixture Basics Challenge
Que 1st Ans:-
Project Sequence Activities are as follows:-
RFQ Received
1st Specification Discussion Meeting
Offer Submission
LOI/PO receipt
Schedule Preparation
BOM Preparation
Design Concept
Customer Approval
Detailed & Drawing release
Manufacturing / BOP Ordering
Mechanical / Electrical Assembly
Quality Inspection
Internal Trial Testing
Online Trial
Packing
Dispatch
Installation as per Layout
Trials & Training at customers
Buyoff meeting
Final Handover
Que 2nd Ans:-
Type of Joining Process is as follows :-
1] Resistance Welding
A) Resistance Spot Welding
B) Resistance Seam Welding
C) Resistance Projection Welding
2] Arc Welding
A) Manual Metal arc welding.
B) Gas - sheild metal arc welding (MIG)
C) Gas - sheild Tungsten arc welding (TIG)
D) Submerged arc welding
E) Plasma arc welding
3] Mechanical Fastening
4] Hemming Process
5] Self- Piercing Riveting
6] Adhesive Bonding
Que 3rd Ans:-
Resistance Welding
Resistance welding, sometimes called electric resistance welding (ERW), is a process by which metals can be joined together by applying pressure and conducting a strong electric current through the metal combination to heat up the welding joint and melt the metals, forging them together.
Resistance welding is generally used to join two plain metal workpieces together. An electric current is delivered to the metal sheets (or any workpieces being joined) through weld electrodes which apply force to the sheets. This force is then converted to heat. The heat is generated so that it melts the metal at the point where they join – the point of ‘resistance’ between the faying surfaces. The electrode then extracts heat from the molten weld area which forms a weld nugget at the point where it solidifies. A force is applied before, during and after a current is applied, which confines the contact area.
It has various forms and applications, and no other materials are needed, which makes it a highly cost-effective process.
Types of Resistance Welding
1. Resistance Spot Welding
Resistance spot welding has been used extensively in the automotive industry for the joining of steel and in the aerospace industry for airframe components made from aluminium alloys. It is one of the oldest and simplest forms of resistance welding, in which a weld nugget is produced by passing an electric current between the two metal components whilst they are held together between electrodes, typically made from copper-based alloys due to their superior conductive properties.
2. Resistance Seam Welding
Resistance seam welding is a variation of the standard spot welding form, however, instead of spot one nugget, a series of overlapping nuggets is produced. This is usually done by replacing the conventional spot welding electrodes with wheels, which turn as the parts are fed between them. The process thus produces a continuously welded seam rather than a single spot. Seam welding is often used in the production of thin sheet, leak-tight containers such as fuel tanks, and is generally unsuitable for welding aluminium.
3. Resistance Projection Welding
Resistance projection welding is a form of resistance welding where the electricity, force, and weld time are concentrated on raised ‘projections’ across the surface. Projection welding is generally used for welds using thicker materials than the thinner metal pieces that spot welding is usually required for, and often not metals. It is used primarily in the electrical, automotive and construction industries.
Que 4th Ans:-
Fusion Welding - Fusion welding is a process that uses heat to join or fuse two or more materials by heating them to a melting point. The process may or may not require the use of 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.
Fusion Welding Processes
Fusion welding processes can be grouped according to the source of the heat, for example, electric arc, gas, electrical resistance and high energy.
These processes include:
Arc Welding Processes - with the most common processes being:
Shielded Metal Arc Welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc welding or stick welding. Suitable for welding ferrous and non-ferrous materials in all positions.
Metal Inert Gas Welding (MIG) and Metal Active Gas welding (MAG), also known as Gas Metal Arc Welding (GMAW). MIG and MAG welding is the most common arc welding process, in which an electric arc forms between a consumable wire electrode and the workpiece leading them to melt and join. Both use a shielding gas to protect the weld from airborne contaminants, or oxidation in the case of MIG welding.
Tungsten Inert Gas Welding (TIG), also known as Gas Tungsten Arc Welding (GTAW). This arc process uses a non-consumable tungsten electrode to create the arc between the electrode and the base plate. Inert shielding gas is used to protect from oxidation or other atmospheric contamination. This process can be used autogenously on thin parts but will require the addition of a wire, rod, or consumable to be added for thicker parts.
Plasma Arc Welding (PAW). This process uses an electric arc created between an electrode and the torch nozzle. The electric arc ionises the gas (usually argon) in the chamber creating what is called a 'plasma.' It is then forced through a fine bore copper nozzle that constricts the arc and directs it to the workpiece, allowing the plasma arc to be separated from the shielding gas (which is usually made from a mixture of argon and hydrogen).
Submerged Arc Welding (SAW). This frequently-used arc welding process uses a continuously fed consumable electrode and a blanket of fusible flux which becomes conductive when molten and provides a current path between the workpiece and the electrode. The flux also prevents spatter and sparks while suppressing ultraviolet radiation and fumes.
Flux Cored Arc Welding (FCAW). Developed as an alternative to SMAW, this process uses a continuously fed consumable electrode with a flux and a constant voltage or constant current power supply. Sometimes using a shielding gas this process can also just use the flux to provide protection from the atmosphere.
Que 5th Ans:-
3-2-1 principle
The best and most effective method of part locating is referred to as the 3-2-1 method.
(3) Minimum 3 locators blocks are established part plane 3 locators or suppose are placed under the workpiece. The 3 locators are usually positioned on the primary location surfaces. The restriction one axial movement downwards and 4 radial movement. Together, the 3 locators restrict 5 degrees of freedom.
(2) Round locating pin in a round hole that defines locating in 4 directions (4- way) perpendicular to the plane previously established. The restriction four axial movements.
(1) Round locating pin in a slot that defines two of the directions of the other (2-way). The restriction two axial movements.
Que 6th Ans:-
Body Coordinate System in BIW
The body coordinate system has been widely used in the Automotive industry for drawing of the 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 place in either two or 3 dimensions
In Genenral BCS is valled as Carline ands Bodyline
X = Lingitudial direction [ Fore & After - F/A ] or [ Fore O line - FOL ]
Y = Transverse direction [ Cross car - C/C ] or [ Center O line - COL ]
Z = Vertical direction [ Up & Down - U/D ] or [ Bottom O line - BOL ]
The origin of the body coordinate system (OX) is defined at the front centre of the vehicle it indicates the length of the car and the coordinates system (OZ) is below its underbody indicates the height of the car and the coordinates system (OY) is the starting point is the centre of the car body indicates the weight of the car.
Que 7th Ans:-
-Body Planes are the reference plane is an Automobiles var these planes used to define the GD&T of all var parts in an Automotive domain.
-Body Planes are 3 mutually perpendicular imaginary planes. These are generally considered to be present at the derives position or sometimes or sometimes at the engine locating or at the front end of the car depending on the customers.
- The measurement from the body planes to the parts are called as Bodyline Dimensions
These Body planes are called as
- FOL front O Line.
- COL Center O Line.
- BOL Body O Line.
- The measurement along FOL or X-axis is called as F/A front Aft.
- The measurement along COL or Y-axis is called a C/C Cross car.
- The measurement along BOL or Z-axis is called U/DUP down
Body Dimensions are essential for the reason stated below
- It defines the exact position of each product the vehicle w.r.t fixed origin.
- It ensures flawless design for assembly.
- While designing lines all the designs are carried out relative to the bodyline viz. fixture, turn and table, etc.
- It consists of the easy location of different parts in a vehicle.
- It aims in creating a Standardized system.
- It consists of Quality checks.