Catia v5_ Biw Welding Fixture Design

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Wednesday, April 25, 2012

BIW WELDING FIXTURE DESIGN

BIW WELDING FIXTURE DESIGN No matter what your knowledge about fixture design, you use the following stages in design of your BIW weld fixture:

Study and understanding of process Concept design Create 3D­Modeling

You study your process You start design by study production process of body­in­white (BIW) this process provides valuable information for the design phase. The purpose of study BIW process includes the following:

The special focus on the structure of a body (BIW) enables you to find the logic and flow of body panels, and the relationships between them. The select of master control point, which are holes or surfaces related to your body part & assembly to arrive at the dimensional integrity of the BIW by giving the steel parts in the correct position during joining. The analyzing of body is made up of several hundreds of stamped components which are joined together by spot welding with welding gun for understanding of welding points and allocate them to welding operations.

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Study of cycle time diagrams, for check reach ability and optimizing it. Cycle time is estimating the required working time for each station.

You create your concept design based on process study Now you can use of process study for defining the design criteria and finding or verifying the concepts. The welding fixture design is created with the following steps: The clamping plans for accurate positioning of components, while the components are aligned to a suitable plane for welding they are designed in the carline plane (as in BIW).

http://learningcatia.blogspot.com/2012/04/biw­welding­fixture­design.html

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CATIA V5: BIW WELDING FIXTURE DESIGN Design of the weld fixture is unit based on clamping plan, therefore there are a number of fixture unit types used in the welding fixtures for the purpose of each unit and due to the complexity and shape of the component geometry, the choice of elements as well as configuration of each unit tends to change from case to case. The check of weld accessibility and spot weld for unrestricted access to each weld point, before and after the fixture design, the accessibility of the weld guns to all the spot points can be simulated and studied thoroughly to avoid guns colliding with other fixture elements.

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You create 3D Modeling fixture

Aug 16 (1)

You need knowledge and experience in 3D Modeling software for creating 3D­Model and 2D drafting, detailing & 3D concept design. The 3D Modeling becomes the basic for following item: Create 3D Modeling of the weld fixture for visualizing the entire fixture in a three­ dimensional environment. 3D Modeling of weld fixture generated by cad software, which lets you detect collisions, check reach ability spot weld and carry out weld accessibility study for ensuring your fixture efficiency. The 3D CAD Model of weld fixture unit enables you to make CAD Model of clamp location plan for ensuring that plan problems and waste are discovered before your fixture drawing to send for manufacturing.

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By 3D Modeling of weld fixture, you can quickly prepare manufacturing drawings.

http://www.plm.automation.siemens.co m/en_us/products/velocity/solidedge/in dex.shtml

PRODUCTION PROCESS OF BODY­IN­WITHE (BIW)

http://www.proengineer.com/index.php

In the study phase of planning process you find or verify the concepts of the body­ in­white manufacturing process. For design welding fixture, trying to understand processes is essential. It is starting with process logic and flow, and defines the relationships between operations.

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Finite Element Analysis Software Suppliers http://www.lmsintl.com/ http://www.fluent.com/

The process study is a solution that to help you quickly define and evaluate process to arrive at the best plan for designing your fixture. The result is process study containing a full description of how a product is assembled, manufactured and increases your profitability by improving critical success factors in your fixture design. The process study allows designer to leverage and optimize existing resources and to better integrate the designing process from beginning to end can not only help designer create fixture faster, but you can also begin design earlier in the overall cycle or even start later, in order to accommodate unanticipated changes. The Assembly Process studying allows evaluating alternatives, coordinating resources, optimizing throughput, plan for multiple variants, implement changes and estimate costs and cycle times, from the very early stages of concept planning through process. Studying, Analyzing and Managing Manufacturing Processes enables you to collaboratively plan and analyzing manufacturing processes for your fixture. You can create optimal design and accommodate multiple plan variations, quicker and faster than ever before. Process study provides a collaborative environment for planning designing processes. A broad range of applications enable you to define and verify body assembly sequences, create clamping plan layout, define the required time for each operation, verify plan performance, perform plan balancing and analyze of spot welding and guns. The body­in­white Manufacturing Process includes:

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Design Tools http://www.onlineconversion.com/ http://www.bayermaterialsciencenafta. com/checklist/index.html http://hongkong01.rs‐online.com/web/ http://www.uspto.gov/main/patents.ht m http://www.freepatentsonline.com/ http://www.download.com/CutePDF‐ Writer/3000‐6675_4‐10544495.html? tag=lst‐0‐1 http://www.delcam.com/general/softw are/ps‐exchange.asp https://sdp‐si.com/eStore/ http://www.matweb.com/ http://textures.forrest.cz/ http://www.planit3d.com/source/textur e_files/textures.html

online help of various CAD packages http://www.kxcad.net/

PLM Education http://www.3ds.com/home/

Automotive body assembly Electric resistance welding Cycle time diagrams

http://learningcatia.blogspot.com/2012/04/biw­welding­fixture­design.html

http://www‐ 01.ibm.com/software/plm/index.html http://www.purdue.edu/dp/PLM/SME/c urriculum.php

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CATIA V5: BIW WELDING FIXTURE DESIGN PLM Forums Automotive body assembly The major process of an automotive body is electric resistance welding. Resistance welding is a group of fusion welding processes that use a combination of heat and pressure to accomplish coalescence and where electric resistance welding is not applicable ,CO2,ARC WELDING and MIG­BRAZING are performed. The body of automotive is made up of several hundreds of stamped components which are joined together by spot welding process.

http://www.coe.org/forums/

PLM News http://www.mcadcafe.com/ http://www.3ds.com/news‐ events/contact‐mag/

Useful software download .

Overall quality of the car body (BIW) and quality of the sub assemblies, apart from quality of each stamped part, depends remarkably on quality of the welded joint. You should study of part joining, welding operations such as spot­welding and define welding points and allocate them to welding operations. The study of welding process can be classified as follow: The number of welding spot

Pipe Flow Software for Fluid Flow and Pressure Drop Calculations. http://www.pipeflow.co.uk/public/cont rol.php?_path=/497/502

On screen PROTRACTOR,CALIPERS,COMPASS http://www.iconico.com

The position and volume number of welding spot The type of welding gun The material and sheet metal thickness for setting of welding condition

University of Alberta ‐ ANSYS Tutorials http://www.mece.ualberta.ca/tutorials /ansys/index.html

Cycle time diagrams Examples for Adams/Car (MSC Software) The cycle time is estimating the required working time of each station. Cycle time study is based on the information such as: Part loading Clamping Gun forward Welding Gun retreat Unclamping Part unloading

PORTABLE WELDING GUN Almost all of the automotive body parts are assembled by resistance spot welding.

http://www.mscsoftware.com/university /software_bundles/adams_car_examples .cfm

The MSC/PATRAN FAQ http://www‐ h.eng.cam.ac.uk/help/amb/programs/fe /prepost/patfaq/patfaq1.html

Designing parametric bevel gears with Catia V5 http://gtrebaol.free.fr/doc/catia/bevel _gear.html

Designing parametric helical gears with Catia V5 http://gtrebaol.free.fr/doc/catia/helica l_gear.html

A spot welder consists of a transformer to obtain a large welding current, timer to control the time in which to feed the current, electrodes to hold welded articles, pressurizing cylinder to apply the necessary for the material being welded.

Designing parametric spur gears with Catia V5

Secondary cable lets necessary current through transformer flow to gun, spring balancer to lighten the welding gun and the cable.

Using internal gears in an epicyclic gearbox

Resistance spot welding is passed between two copper electrodes, the process can be performed by the operator holding a portable welding machine and moving it around the parts being welded. These portable machines called portable welding guns. The manual weld guns can have easy access to weld the components together. The resistance spot welding machines are classified according to combinations of individual sections as follows:

http://gtrebaol.free.fr/doc/catia/spur_ gear.html

http://gtrebaol.free.fr/doc/catia/epicyc lic.html

Example categories for MSC.Patran, MSC.Nastran, and MSC.Nastran for Windows http://www.mscsoftware.com/support/ online_ex/Library.cfm

Followers

Fixed type Stud type Portable type: Conventional weld gun Integral weld gun

http://learningcatia.blogspot.com/2012/04/biw­welding­fixture­design.html

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CATIA V5: BIW WELDING FIXTURE DESIGN Followers (11)

Conventional weld gun Conventional weld guns have a large transformer located remotely from the weld gun. The welding current is delivered to the weld gun arms through a large, water­cooled secondary cable.

J type or C type S type or X type

The conventional weld guns were used in various applications because the weld controllers did not have the ability to detect and react to any hazard associated with using primary power connected directly to the weld gun.

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Integral weld gun

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Integral weld gun or tarn's guns have a smaller transformer located right on the weld gun, from which the current is delivered through short jumpers or shunts that are air cooled. Tran's guns are also called weld guns, because the transformer is part of the unit.

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The two configurations of portable tarn's guns are: C gun Scissors gun

For example C gun for welding around a door opening on a small flange and Scissors gun for welding large, deep boxes requiring a long reach. There are following characterizes for tarn's guns: Design Flexibility Ergonomics Cost efficiency

at 9:53 AM

Posted by Rahul Gupta

Labels: BIW Welding Fixture, CATIA Tips, Generative Shape Design 2 comments: Precision engineers said... The overall program consists of twelve different weld fixtures. Each fixture can accommodate an average of three or four different models. May 25, 2013 at 12:11 AM

MANJUNATH HABALAKATTI said... its very informative.. May 25, 2016 at 8:59 AM Post a Comment Links to this post Create a Link

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