Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing

The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at high-stress regions and increasing their number at optimized locations significantly reduces post-coating deviations & rejections. Implementation of this approach led to a measurable improvement in Hood to adjacent interface visible gap consistency (by 40-50%) and flushness alignment (by 60-70%), as quantified through statistical process control metrics. The optimized rod setup minimizes the cost of rejection, cost of post-process rework, enhances coating uniformity and ensures tighter tolerances in final vehicle assembly without substantially reinforcing the Hood panel which further helps to reduce the carbon footprint by improving fuel efficiency and improving the Safety crash performance of the vehicle. These findings underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional inaccuracies, overall weight reduction & crash worthiness of vehicle.