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CATIAV5:BIWWELDINGFIXTUREDESIGN
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Wednesday, April 25, 2012

BIW WELDING FIXTURE DESIGN

BIWWELDINGFIXTUREDESIGN
Nomatterwhatyourknowledgeaboutfixturedesign,youusethefollowingstagesin
designofyourBIWweldfixture:

Studyandunderstandingofprocess
Conceptdesign
Create3DModeling

Youstudyyourprocess
Youstartdesignbystudyproductionprocessofbodyinwhite(BIW)thisprocess
providesvaluableinformationforthedesignphase.
ThepurposeofstudyBIWprocessincludesthefollowing:

Thespecialfocusonthestructureofabody(BIW)enablesyoutofindthelogicand
flowofbodypanels,andtherelationshipsbetweenthem.
Theselectofmastercontrolpoint,whichareholesorsurfacesrelatedtoyourbody
part&assemblytoarriveatthedimensionalintegrityoftheBIWbygivingthesteel
partsinthecorrectpositionduringjoining.
Theanalyzingofbodyismadeupofseveralhundredsofstampedcomponents
whicharejoinedtogetherbyspotweldingwithweldinggunforunderstandingof
weldingpointsandallocatethemtoweldingoperations.

Pages
BAD HABIT IN CATIA 'neverdo' list
CATIA V5 FUNDAMENTAL
DMU

Studyofcycletimediagrams,forcheckreachabilityandoptimizingit.Cycletimeis
estimatingtherequiredworkingtimeforeachstation.

Youcreateyourconceptdesignbasedonprocessstudy
Nowyoucanuseofprocessstudyfordefiningthedesigncriteriaandfindingorverifying
theconcepts.
Theweldingfixturedesigniscreatedwiththefollowingsteps:
Theclampingplansforaccuratepositioningofcomponents,whilethecomponents
arealignedtoasuitableplaneforweldingtheyaredesignedinthecarlineplane
(asinBIW).

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

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Designoftheweldfixtureisunitbasedonclampingplan,thereforetherearea
numberoffixtureunittypesusedintheweldingfixturesforthepurposeofeachunit
andduetothecomplexityandshapeofthecomponentgeometry,thechoiceof
elementsaswellasconfigurationofeachunittendstochangefromcasetocase.
Thecheckofweldaccessibilityandspotweldforunrestrictedaccesstoeachweld
point,beforeandafterthefixturedesign,theaccessibilityoftheweldgunstoallthe
spotpointscanbesimulatedandstudiedthoroughlytoavoidgunscollidingwith
otherfixtureelements.

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Youcreate3DModelingfixture

Aug 16 (1)

Youneedknowledgeandexperiencein3DModelingsoftwareforcreating3DModeland
2Ddrafting,detailing&3Dconceptdesign.
The3DModelingbecomesthebasicforfollowingitem:
Create3DModelingoftheweldfixtureforvisualizingtheentirefixtureinathree
dimensionalenvironment.
3DModelingofweldfixturegeneratedbycadsoftware,whichletsyoudetect
collisions,checkreachabilityspotweldandcarryoutweldaccessibilitystudyfor
ensuringyourfixtureefficiency.
The3DCADModelofweldfixtureunitenablesyoutomakeCADModelofclamp
locationplanforensuringthatplanproblemsandwastearediscoveredbeforeyour
fixturedrawingtosendformanufacturing.

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Total Pageviews

92949
Mainstream PLM Suppliers
http://usa.autodesk.com/adsk/servlet/h
ome?siteID=123112&id=129446
http://www.3ds.com/index.php?id=172
http://www.plm.automation.siemens.co
m/en_us/products/nx/

By3DModelingofweldfixture,youcanquicklypreparemanufacturingdrawings.

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

PRODUCTIONPROCESSOFBODYINWITHE(BIW)

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

Inthestudyphaseofplanningprocessyoufindorverifytheconceptsofthebody
inwhitemanufacturingprocess.Fordesignweldingfixture,tryingtounderstand
processesisessential.Itisstartingwithprocesslogicandflow,anddefinesthe
relationshipsbetweenoperations.

http://www.solidworks.com/

Finite Element Analysis Software

Suppliers
http://www.lmsintl.com/
http://www.fluent.com/

Theprocessstudyisasolutionthattohelpyouquicklydefineandevaluate
processtoarriveatthebestplanfordesigningyourfixture.Theresultisprocess
studycontainingafulldescriptionofhowaproductisassembled,manufactured
andincreasesyourprofitabilitybyimprovingcriticalsuccessfactorsinyourfixture
design.
Theprocessstudyallowsdesignertoleverageandoptimizeexistingresourcesand
tobetterintegratethedesigningprocessfrombeginningtoendcannotonlyhelp
designercreatefixturefaster,butyoucanalsobegindesignearlierintheoverall
cycleorevenstartlater,inordertoaccommodateunanticipatedchanges.
TheAssemblyProcessstudyingallowsevaluatingalternatives,coordinating
resources,optimizingthroughput,planformultiplevariants,implementchanges
andestimatecostsandcycletimes,fromtheveryearlystagesofconceptplanning
throughprocess.
Studying,AnalyzingandManagingManufacturingProcessesenablesyouto
collaborativelyplanandanalyzingmanufacturingprocessesforyourfixture.You
cancreateoptimaldesignandaccommodatemultipleplanvariations,quickerand
fasterthaneverbefore.
Processstudyprovidesacollaborativeenvironmentforplanningdesigning
processes.Abroadrangeofapplicationsenableyoutodefineandverifybody
assemblysequences,createclampingplanlayout,definetherequiredtimefor
eachoperation,verifyplanperformance,performplanbalancingandanalyzeof
spotweldingandguns.
ThebodyinwhiteManufacturingProcessincludes:

http://www.ansys.com/
http://www.simulia.com/index.html
http://www.mscsoftware.com/

Design Tools
http://www.onlineconversion.com/
http://www.bayermaterialsciencenafta.
com/checklist/index.html
http://hongkong01.rsonline.com/web/
http://www.uspto.gov/main/patents.ht
m
http://www.freepatentsonline.com/
http://www.download.com/CutePDF
Writer/30006675_410544495.html?
tag=lst01
http://www.delcam.com/general/softw
are/psexchange.asp
https://sdpsi.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/

Automotivebodyassembly
Electricresistancewelding
Cycletimediagrams

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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CATIAV5:BIWWELDINGFIXTUREDESIGN
PLM Forums
Automotivebodyassembly
Themajorprocessofanautomotivebodyiselectricresistancewelding.Resistance
weldingisagroupoffusionweldingprocessesthatuseacombinationofheatand
pressuretoaccomplishcoalescenceandwhereelectricresistanceweldingisnot
applicable,CO2,ARCWELDINGandMIGBRAZINGareperformed.
Thebodyofautomotiveismadeupofseveralhundredsofstampedcomponents
whicharejoinedtogetherbyspotweldingprocess.

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

PLM News
http://www.mcadcafe.com/
http://www.3ds.com/news
events/contactmag/

Useful software download

.

Overallqualityofthecarbody(BIW)andqualityofthesubassemblies,apartfrom
qualityofeachstampedpart,dependsremarkablyonqualityoftheweldedjoint.
Youshouldstudyofpartjoining,weldingoperationssuchasspotweldingand
defineweldingpointsandallocatethemtoweldingoperations.
Thestudyofweldingprocesscanbeclassifiedasfollow:
Thenumberofweldingspot

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

Thepositionandvolumenumberofweldingspot
Thetypeofweldinggun
Thematerialandsheetmetalthicknessforsettingofweldingcondition

University of Alberta ANSYS Tutorials

http://www.mece.ualberta.ca/tutorials
/ansys/index.html

Cycletimediagrams
Examples for Adams/Car (MSC Software)
Thecycletimeisestimatingtherequiredworkingtimeofeachstation.
Cycletimestudyisbasedontheinformationsuchas:
Partloading
Clamping
Gunforward
Welding
Gunretreat
Unclamping
Partunloading

PORTABLEWELDINGGUN
Almostalloftheautomotivebodypartsareassembledbyresistancespot
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

Aspotwelderconsistsofatransformertoobtainalargeweldingcurrent,timer
tocontrolthetimeinwhichtofeedthecurrent,electrodestoholdwelded
articles,pressurizingcylindertoapplythenecessaryforthematerialbeing
welded.

Designing parametric spur gears with

Catia V5

Secondarycableletsnecessarycurrentthroughtransformerflowtogun,
springbalancertolightentheweldinggunandthecable.

Using internal gears in an epicyclic

gearbox

Resistancespotweldingispassedbetweentwocopperelectrodes,the
processcanbeperformedbytheoperatorholdingaportableweldingmachine
andmovingitaroundthepartsbeingwelded.
Theseportablemachinescalledportableweldingguns.Themanualweldguns
canhaveeasyaccesstoweldthecomponentstogether.
Theresistancespotweldingmachinesareclassifiedaccordingto
combinationsofindividualsectionsasfollows:

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

Fixedtype
Studtype
Portabletype:
Conventionalweldgun
Integralweldgun

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

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Followers(11)

Conventionalweldgun
Conventionalweldgunshavealargetransformerlocatedremotelyfromthe
weldgun.Theweldingcurrentisdeliveredtotheweldgunarmsthrougha
large,watercooledsecondarycable.

JtypeorCtype
StypeorXtype

Theconventionalweldgunswereusedinvariousapplicationsbecausethe
weldcontrollersdidnothavetheabilitytodetectandreacttoanyhazard
associatedwithusingprimarypowerconnecteddirectlytotheweldgun.

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Integralweldgun

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Integralweldgunortarn'sgunshaveasmallertransformerlocatedrighton
theweldgun,fromwhichthecurrentisdeliveredthroughshortjumpersor
shuntsthatareaircooled.
Tran'sgunsarealsocalledweldguns,becausethetransformerispartofthe
unit.

There was an error in this gadget

Thetwoconfigurationsofportabletarn'sgunsare:
Cgun
Scissorsgun

ForexampleCgunforweldingaroundadooropeningonasmallflangeand
Scissorsgunforweldinglarge,deepboxesrequiringalongreach.
Therearefollowingcharacterizesfortarn'sguns:
Design
Flexibility
Ergonomics
Costefficiency

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
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