Saturday, May 10, 2014

Electrochemical Machining - Lecture - 2014




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Tuesday, May 6, 2014

Automobile Seat

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Automobile Body Shop - Processes

BMW Body Shop

The sleek lines, the flawless fit between door and frame, quarter panel and hood; ensure performance of the vehicle, through aerodynamic efficiency, frame-welded stability and the tightest-fitting doors.

It all happens at the Body Shop.

The Body Shop is comprised of two separate lines: one line for X5/X6 and a separate line for X3.
The state-of-the-art X5/X6 Body Shop contains more than 380 robots.
About 450 team members are there in the body shop.
Each car has about 7,500 spot welds and 350 stud welds.
From start to finish, it takes about 6 hours to build a complete car body.
One car body contains approximately 80 meters (260 feet) of sealer, 2 meters (6.5 feet) of MIG Welds, and 80 rivets.
One car body is made up of 400 individual parts.
On the X3 line, the hang-on parts area where doors, hood and tailgate are attached is completely automated. This is the first fully automated hang-on fit line in the BMW Group Production Network.

https://www.bmwusfactory.com/manufacturing/production-process/body-shop/
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Bonnet - Car Component - Sub-assembly

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Automobile - Car Components - Manufacturing Processes


List  - Auto parts  -  Automobile - Car


1 Body, Door and Windows
2 Electrical and electronics
3 Interior
4 Powertrain and chassis
5 Miscellaneous auto parts





Body

Body in white manufacture - Bibliography - YouTube Videos

Body components, including windows and trim:
Bonnet/hood
Bonnet/hood latch
Bumper
Unexposed bumper
Exposed bumper
Cowl screen
Decklid
Fascia rear and support
Fender (wing or mudguard)
Front clip
Front fascia and header panel
Grille (also called grill)
Pillar and hard trim
Quarter panel
Radiator core support
Rocker panel
Roof rack
Spoiler
Front spoiler (air dam)
Rear spoiler (wing)
Trim package
Trunk/boot/hatch
Trunk/boot latch
Valance
Welded assembly

Doors

Outer door handle
Inner door handle
Door control module
Door seal
Door watershield
Hinge
Door latch
Door lock and power door locks
Center-locking
Fuel tank (or fuel filler) door

Windows

Glass
Sunroof
Sunroof motor
Window motor
Window regulator
Windshield (also called windscreen)
Windshield washer motor
Window seal


Electrical and electronics

Audio/video devices
Antenna assembly
Antenna cable
Radio and media player
Other devices
Speaker
Tuner
Subwoofer

Charging system
Alternator
Alternator bearing
Alternator bracket
Alternator fan
Other alternator parts

Electrical supply system
Battery
Performance battery
Battery box
Battery cable terminal
Battery cable
Battery control system
Battery plate
Battery tray
Voltage regulator

Gauges and meters
Ammeter
Clinometer
Dynamometer
Fuel gauge
Hydrometer
Odometer (also called milometer or mileometers)
Speedometer
Tachometer (also called rev counters)
Temperature gauge
Tire pressure gauge
Vacuum gauge
Voltmeter
Water temperature meter

Ignition system
Coil wire
Distributor
Electronic timing controller
Ignition box
Ignition coil
Ignition coil parts
Ignition magneto
Spark plug

Lighting and signaling system
Engine bay lighting
Fog light (also called foglamp)
Halogen
Headlight (also called headlamp)
Headlight motor
Interior light and lamp
License plate lamp (also called number plate lamp or registration plate lamp)
Side lighting
Tail light
Tail light cover

Sensors
Airbag sensor
Automatic transmission speed sensor
Camshaft position sensor
Coolant temperature sensor
Crankshaft position sensor
Engine sensor
Fuel level sensor
Fuel Pressure sensor
Knock sensor
Light sensor
Oil pressure sensor
O2 sensor
Mass flow sensor

Starting system
Starter
Starter drive
Starter motor
Starter solenoid
Glowplug

Switches
Battery
Door switch
Ignition switch
Power window switch
Steering column switch
Switch cover
Switch panel
Thermostat
Frame switch
Parts and functions of starter system

Wiring harnesses
(wiring loom or cable loom)
Air conditioning harness
Engine compartment harness
Interior harness

Miscellaneous
Air bag control module
Alarm and siren
Central locking system
Chassis control computer
Cruise control computer
Door contact
Engine computer and management system
Engine control unit
Fuse
Fuse box
Ground strap
Grab Handle (aka "Oh S***" Handle)
Performance chip
Performance monitor
Relay connector
Remote lock
Shift improver
Speed controller
Speedometer calibrator
Transmission computer
Wiring connector

Interior
Floor components and parts
Carpet and other floor material
Center console (front and rear)
Other components[edit]
Trap (secret compartment)

Car seat
Armrest
Bench seat
Bucket seat
Children and baby car seat
Fastener
Headrest
Seat belt
Seat bracket
Seat cover
Seat track
Other seat components


Powertrain and chassis

Braking system
Anti-lock braking system (ABS)
ABS steel pin
Adjusting mechanism (adjuster star wheel)
Anchor
Bleed nipple
Brake backing plate
Brake backing pad
Brake cooling duct
Brake disc
Brake drum
Brake line
Brake pad
Brake pedal
Brake piston
Brake pump
Brake roll
Brake rotor
Brake servo
Brake shoe
Brake lining
Shoe web
Brake warning light
Calibrated friction brake
Caliper
Combination valve
Dual circuit brake system
Hold-down springs (retainer springs)
Hose
Brake booster hose
Air brake nylon hose
Brake duct hose
Hydraulic booster unit
Load-sensing valve
Master cylinder
Metering valve
Other braking system parts
Park brake lever/handle (hand brake)
Pressure differential valve
Proportioning valve
Reservoir
Shoe return spring
Vacuum brake booster
Wheel cylinder (slave cylinder)
Wheel stud

Engine components and parts
Diesel engine, petrol engine (gasoline engine)
Accessory belt
Air duct
Air intake housing
Air intake manifold
Camshaft
Camshaft bearing
Camshaft fastener
Camshaft follower
Camshaft locking plate
Camshaft pushrod
Camshaft spacer ring
Connecting rod
Connecting rod bearing
Connecting rod bolt
Connecting rod washer
Crank case
Crank pulley
Crankshaft
Crankshaft oil seal
Cylinder head
Cylinder head cover
Other cylinder head cover parts
Cylinder head gasket
Distributor
Distributor cap
Drive belt
Engine block
Engine block parts
Engine cradle
Engine shake damper and vibration absorber
Engine valve
Fan belt
Gudgeon pin (wrist pin)
Harmonic balancer
Heater
Mounting
Piston
Piston pin and crank pin
Piston pin bush
Piston ring and circlip
Poppet valve
PCV valve (positive crankcase ventilation valve)
Pulley part
Rocker arm
Rocker cover
Starter motor
Starter pinion
Starter ring
Turbocharger and supercharger
Tappet
Timing tape
Valve cover
Valve housing
Valve spring
Valve stem seal
Water pump pulley

Engine cooling system
Air blower
Coolant hose
Cooling fan
Fan blade
Fan clutch
Radiator
Radiator bolt
Radiator shroud
Radiator gasket
Radiator pressure cap
Water neck
Water neck o-ring
Water pipe
Water pump
Water pump gasket
Water tank

Engine oil system
Oil filter
Oil gasket
Oil pan
Oil pipe
Oil pump
Oil strainer

Exhaust system

Catalytic converter
Exhaust clamp and bracket
Exhaust flange gasket
Exhaust gasket
Exhaust manifold
Exhaust manifold gasket
Exhaust pipe
Heat shield
Heat sleeving and tape
Resonator
Muffler (silencer)
Spacer ring
ely

Fuel supply system
Air filter
Carburetor
Carburetor parts
Choke cable
EGR valve
Fuel cap
Fuel cell
Fuel cell component
Fuel cooler
Fuel distributor
Fuel filter
Fuel filter seal
Fuel injector
Fuel injector nozzle
Fuel pump
Fuel pump gasket
Fuel pressure regulator
Fuel rail
Fuel tank
Fuel tank cover
Fuel water separator
Intake manifold
Intake manifold gasket
LPG (Liquefied petroleum gas) system assembly
Throttle body

Suspension and steering systems
Beam axle
Control arm
Constant-velocity axle
Constant-velocity joint
Idler arm
Kingpin
Panhard rod
Pitman arm
Power steering assembly and component
Rack end
Shock absorber
Spindle
Spring
Air spring
Coil spring
Leaf and parabolic leaf spring
Rubber spring
Spiral spring
Stabilizer bars and link
Steering arm
Steering box
Steering column assembly
Steering rack (a form of steering gear; see also rack and pinion and recirculating ball)
Steering shaft
Steering wheel (driving wheel)
Strut
Stub axle
Suspension link and bolt
Tie bar
Tie rod
Tie rod end
Trailing arm

Transmission system
Adjustable pedal
Axle shaft
Bell housing
Cam belt
Other belts
Carrier assembly
Chain wheel and sprocket
Clutch assembly
Clutch cable
Clutch disk
Clutch fan
Clutch fork
Clutch hose
Clutch lever
Clutch lining
Clutch pedal
Clutch pressure plate
Clutch shoe
Clutch spring
Differential
Differential case
Pinion bearing
Differential clutch
Spider gears
Differential casing
Differential flange
Differential gear
Differential seal
Flywheel
Flywheel ring gear
Gear
Gear coupling
Gear pump
Gear ring
Gear stick (gearstick, gear lever, selection lever, shift stick, gear shifter)
Gearbox
Idler gear
Knuckle
Master cylinder
Output shaft
Pinion
Planetary gear set
Prop shaft (drive shaft, propeller shaft)
Shift cable
Shift fork
Shift knob
Shift lever
Slave cylinder
Speed reducer
Speedometer gear
Steering gear
Torque converter
Transaxle housing
Transfer case
Transmission gear
Transmission pan
Transmission seal and bonded piston
Transmission spring
Transmission yolk
Universal joint (UJ, cardan joint)

Miscellaneous auto parts

Air conditioning system (A/C)
.

A/C clutch
A/C compressor
A/C condenser
A/C hose
A/C kit
A/C relay
A/C valve
A/C expansion valve
A/C low-pressure valve
A/C schrader valve
A/C INNER PLATE
A/C COOLER
A/C Evaporator
Bearings[edit]
Ball joint
Grooved ball bearing
Needle bearing
Roller bearing
Sleeve bearing

Hoses
Fuel vapour hose
Reinforced hose (high-pressure hose)
Non-reinforced hose
Washer hose

Other miscellaneous parts
Adhesive tape and foil
Air bag
Bolt cap
Bracket (aluminium, iron, and magnesium bracket)
License plate bracket
Cables
Speedometer cable
Cotter pin
Decal
Dashboard
Center console
Glove compartment
Drag link
Dynamic seal
Fastener
Gasket: Flat, moulded, profiled
Hood and trunk release cable
Horn and trumpet horn
Injection-molded parts
Instrument cluster
Label
Mirror
Mount and mounting
Name plate
Nut
Flange nut
Hex nut
O-ring
Paint
Rivet
Rubber (extruded and molded)
Screw
Shim
Sun visor
Washer

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Monday, April 28, 2014

Pressure Die Casting Automotive Components

Low pressure die casting


Low pressure die casting is a well-known casting process, especially for aluminium wheels
in passenger cars. The process is also used in the production of big V-engine blocks in
hypereutectic aluminium alloys and in the casting of air-cooled cylinder heads for motor
cycles.

The casting unit of a low-pressure machine consists of a pressure-tight holding furnace, the
pressure control unit, the hydraulic die manipulators and usually one die for the casting.



High pressure die castings 




Filling speed and intensification pressure differentiates high-pressure die casting 
from most other casting processes. 
 After liquid metal is transferred to the shot sleeve (s. fig. below), the plunger slowly 
closes to shut-off the filling port. 


The plunger is then moved towards the die at a controlled but high speed in order to 
fill the die cavity. 
 With the potential for highly automated operation, the high-pressure die casting 
(HPDC) process is capable of extremely high levels of productivity. 
 HPDC machines are size rated by the closing force (s. figs.) 

The pressure cycle in a modern HPDC machine is closely controlled in all stages. 
 Filling times are typically on the order of 10-25 milliseconds. 
 Once the die is filled, pressures, which may exceed 70 MPa, are maintained on the 
casting, using an accumulator, until solidification is complete (third stage, at right) 
 With the potential for highly automated operation, the high-pressure die 
casting process is capable of extremely high levels of productivity. 
 Multiple hydraulic circuits are used depending on the plunger speed needed at each 
stage as shown below. 



To be die cast, engine blocks must designed with an open deck 

 
The common size range and close tolerances have been used to good effect in defining the 
hydraulic network in large transmission cases shown above. The Belt Tensioners (below) are 
typical of small die cast parts: 


Physical design considerations: 
 Only straight steel core pulls can be used to define internal passages. 
 Core pulls increase tooling costs. 
 Sand coring is generally not possible. 
 Inserts can frequently be cast into the part. Hollow tubes, threaded inserts to fill out 
bosses, engine bore liners, and wear resistant inserts are common. 
 Feeding of shrinkage is via the gates alone; parts should be designed with as uniform 
a thickness as possible. 
 
Metallurgical design considerations: 
 Part ductility is limited by process considerations to <3% on average. 
 Die castings should not be used for load bearing safety critical parts. 
 Die castings are not heat treatable. 
 Die casting are generally produced using secondary (recycled) alloys; this reduces 
cost. 
 Fatigue properties of die castings are good so long as the very smooth as-cast 
surface is not machined away. 

http://www.alueurope.eu/wp-content/uploads/2012/01/AAM-Manufacturing-1-Casting-methods.pdf

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Gravity Die Casting - Automotive Components

Gravity die casting is one of the standard processes for the manufacture of high-integrity
automotive castings. It represents proven and absolute precision technology for the
production of large batch quantities. This process is used in carousel casting units or in
shuttle technique particularly for the manufacture of engine castings.

Optimum heat dissipation from the solidifying casting through the die leads to short
solidification times. This results in castings which have good mechanical properties,
especially after an additional heat treatment.


In addition to producing ever more complicated cylinder heads for petrol and diesel engines,
gravity die casting is also used for the manufacture of diesel engine blocks with cast-in grey
iron liners

4 Valve Cylinder Head
3 Cylinder Diesel engine block

http://www.alueurope.eu/wp-content/uploads/2012/01/AAM-Manufacturing-1-Casting-methods.pdf
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