1.

The Product finalisation and project implementation is to be done using simul

taneous engineering principles.
2. Manufacturing Engineering sources to be on board during the product designing
stage.
3. Minimise the total quantity of individual panels / parts required.
4. Prototypes to be built using production intent stampings and BIW assemblies
5. Consider tolerance build up, and either
Use slippage joints where practicable.
Vary tolerance on components to minimise growth of the assembly.
6. Avoid use of Arc welding / Brazing / Butt Joints to improve quality and reduc
e costs.
7. Locations holes used more than once during the BIW build process must be a fl
anged hole to maintain assembly consistency.
8. Gauge hole tolerances :-
Minimum on Dia. 0.2mm
Preferred on Dia. 0.3mm
Surfaces containing gauge holes must not be formed after piercing this m
ay cause distortion and positional dimension will vary due to Material thickness
variation, Die wear, Flanging / Forming process.
9. Whilst it is possible to match surface in more than one plane where possible,
this should be avoided to minimise errors and/or reduce costs.
10. Ensure panels and assemblies are made foolproof.
11. Provide co-ordinating holes in panels / assemblies.
12. Use Pierce nuts in preference to weld nuts.
13. All matching surfaces to be indicated on the product drawing.
BIW Assembly:
37. Ensure adequate access for welding.
38. Ensure to use minimum types of welding guns.
39. Spot weld areas to be accessible.
40. Ensure that location holes given on flat surfaces.
41. Welding dissimilar metal thickness:-
Resistance spot welding can weld dissimilar metal thickness up to a rati
on 3:1
This requires a larger electrode contact tip against the thicker metal.
When welding 3 dissimilar metal thicknesses the thinnest must be innermost.
Painting point of view.
Provide adequate
Paint Access holes.
Paint Drainage / Holes depressions
Air Release holes.
Wax Injection holes / Depressions.
50. Ensure design of component will not cause hold back of paint.
51. Ensure paint surface is not damaged by after paint operations i.e. drilling
holes.
52. Ensure bolt on parts will not vibrate thereby causing paint damage and poten
tial corrosion.
Generally in automobile industry CRCA sheets are used for Body panels. The broa
d classification of this CRCA steel sheets is given in the following table indic
ating its equivalents in other standards
Introduction In producing a Body in white ( Body weld assembly) the following
processes are involved :-
1. Resistance Welding
a) Spot Welding.
b) Seam Welding
c) Projection Welding
d) Butt Welding
2. MIG Welding Metal inert gas welding
a) Co2 MIG b) Argon MIG c) Co2 + Argon MIG
3. Gas Welding
4. Brazing
5. Soldering
6. Polishing & Buffing
7. Hemming or Clinching
8. Rivetting
9. Drilling
10.Flow drilling/Tapping