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BIW Resistance Spot Weld Parameter Standardization through Parameter Optimization across Various Sheet Metal Panel Combinations

BSA Crescent Institute of Science & Tech-Ganesan Selvam, Sebastian Prince Arockia Doss
Mahindra Research Valley-Muniya Gounder Kannan, Ramalingam Thiruppathi, Naga Sheshank Voppuru
Published 2018-07-09 by SAE International in United States
Body in White (BIW) is one of the critical aggregates of an automobile. Establishing the quality parameters during body manufacturing is essential to achieve robust BIW structure. Spot weld integrity and dimensional accuracy are the two major quality parameters of a BIW. Weld integrity plays an important role in achieving dimensional accuracy and structural stability. Various combinations of sheet metals are joined together to form a BIW structure. Spot weld parameter selection is one of the critical activity and needs to be programmed for the various combinations of sheet metals. Weld parameter for the various combinations are calculated with the resistance of the joining sheet metals thicknesses. The calculated parameters are validated with the coupon test (or) peel test and it requires several iterations to establish weld integrity of the different combinations and the selected parameters get registered in the weld controller. The conventional process consumes a large quantity of weld coupons for destructive testing and weld parameters of every combination become unique. Maintaining the records of several unique weld parameter is a complicated activity…
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Implementation of Lean Approaches in Proto Body Build to Improve Productivity and Flexibility

B S Abdur Rahman University-Prince Arockia Doss Sebastian
Mahindra Research Valley-Ganesan Selvam, Surya Prakash Vaidhyanathan, Mohamed Zaheer Abdulla, Vedantham Baskaran
Published 2017-07-10 by SAE International in United States
Lean approaches are being implemented in various manufacturing facilities across the globe. The application of lean approaches are extended to Body proto build shop to maximize the efficiency of the shop with lesser floor space and optimized equipment. Weld fixture, Weld equipment and assembly tools are the major tools required essentially for proto BIW assembly. This paper explains how the Weld equipment planning was carried out with lean approaches and implemented effectively in proto body assembly shop. The implemented lean concepts are compared with Italy and Japanese proto body build makers to validate the frugal planning of the facility for the said intent. The implemented facility is capable of producing more than a model at a time. Weld parameter selection for weld gun, gun movement to the fixture with minimized change over time and movable weld gun gantry are the lean approaches implemented.
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