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biw Fixture design interview questions

How should you prepare for the biw fixture design interview?

Dear Friends,

Most engineers working in the BIW fixture domain change their jobs for various reasons, such as career growth, market situation, and others. If you are a fresher or experienced engineer, you may be curious about the types of questions that will be asked in a job interview.

There is no one-size-fits-all answer to this question, as the specific questions that will be asked will depend on the job requirement, the company, the work area (OEM, Tier 1, line builder, or engineering service company), the experience of the interviewer, and what you have written in your resume.

However, I will try to give you a few examples of questions that you may be asked, especially if the interviewer is looking for someone to do BIW fixture design and detailing work

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biw fixture design interview question and answers

Mastering BIW Fixture Design Techniques: Insights from Experts

In this video, we’ll share insights on BIW fixture design techniques from an experienced professional. BIW fixture design is a critical element of job-oriented mechanical design courses, and it can take some work to get the right results the first time. In this video, we’ll share tips on designing BIW fixtures using the Catia V5 software. After watching this video, you’ll have the skills to produce high-quality fixtures quickly and efficiently! Learn in and out of BIW Fixture Design from industry experts #design #mcad #catia #biwfixturedesign. In this lecture, we will discuss the basics of BIW fixture design. We will cover the different types of BIW fixtures, the factors that need to be considered when designing BIW fixtures, and the design process for BIW fixtures.

What is BIW Fixture Design? BIW fixture design designs fixtures that hold body-in-white (BIW) components in place during manufacturing. BIW fixtures are an essential part of the manufacturing process, and they require the skills and expertise of a mechanical design engineer. Types of BIW Fixtures There are many different BIW fixtures, each with its specific purpose. Some of the most common BIW fixtures include Welding, Measuring, Assembling, and Painting. Factors to Consider When Designing BIW Fixtures Many factors need to be considered when designing BIW fixtures. Some of the most critical factors include The type of BIW component that the fixture will be used for, The manufacturing process that the fixture will be used in, The accuracy requirements of the fixture, and The cost of the fixture Design Process for BIW Fixtures. The design process for BIW fixtures typically involves the following steps:

Define the needs of the fixture.
Select the materials for the fixture.
Design the fixture.
Build the fixture.
Test the fixture.

Conclusion In this lecture, we discussed BIW fixture design basics. We have covered the different types of BIW fixtures, the factors that need to be considered when designing BIW fixtures, and the design process for BIW fixtures. I hope this lecture has been informative. Thank you for watching!

Do you need to do hardening for Mylar? Which hardening process?

yes, we do require hardening of Mylar to avoid wear of mylar. If not hardened, size will get reduced over the period due to continuous use and which will result in accuracy or assy. Hardening also increases the durability of the material and makes it more resistant to wear and tear. Additionally, it can also help to protect the material from corrosion and weathering. We are doing flame hardening or induction hardening on mylar. This hardening process helps to extend the life of the material and ensure its accuracy. It also helps to reduce the cost of maintenance, as hardened Mylar is less prone to damage.

What is Induction hardening

Induction hardening is a heat treatment process that uses electromagnetic induction to generate heat in a metal part. The part is then quenched rapidly to produce a hardened surface layer. Induction hardening is a very fast and efficient process, and it can be used to harden specific areas of a part without affecting the properties of the part as a whole. Induction hardening is typically used on ferrous materials, such as steel. However, it can also be used on some non-ferrous materials, such as copper and aluminum. The induction hardening process is divided into two stages: Induction heating: An induction coil is placed around the part to be hardened. A high-frequency alternating current is passed through the coil, which creates a magnetic field. The magnetic field induces eddy currents in the part, which heat the part up. Quenching: Once the part has been heated to the desired temperature, it is quenched rapidly. This is typically done by immersing the part in water or oil. The rapid cooling transforms the microstructure of the surface layer of the part, making it harder. Induction hardening is used in a wide variety of applications, including: Automotive parts (e.g., gears, shafts, crankshafts) Aerospace parts (e.g., landing gear, engine components) Industrial machinery (e.g., bearings, gears, rolls) Tools and dies Medical devices Induction hardening is a very versatile and effective process for improving the wear resistance, fatigue strength, and impact strength of metal parts. Here are some of the advantages of induction hardening: It is a very fast process, and parts can be hardened in seconds. It is very efficient, and very little energy is wasted. It is a very precise process, and specific areas of a part can be hardened without affecting the properties of the part as a whole. It is a very clean process, and there is no need for any hazardous chemicals. Induction hardening is a widely used process in the manufacturing industry, and it is a valuable tool for improving the properties of metal parts.

What is Flame hardening

Flame hardening is a surface hardening process that uses a high-temperature flame to heat the surface of a metal part, followed by rapid quenching. The quenching process typically involves immersing the part in water or oil, which rapidly cools the surface layer of the part. This rapid cooling transforms the microstructure of the surface layer, making it harder. Flame hardening is typically used on ferrous materials, such as steel. However, it can also be used on some non-ferrous materials, such as cast iron and copper alloys. Flame hardening is a very versatile process, and it can be used to harden a wide variety of parts, including gears, shafts, bearings, and tools. It is also a very cost-effective process, and it is well-suited for high-volume production. Here are some of the advantages of flame hardening: It is a very fast process, and parts can be hardened in seconds. It is a very versatile process, and it can be used to harden a wide variety of parts. It is a very cost-effective process, and it is well-suited for high-volume production. It is a relatively simple process to implement and operate. Flame hardening is a widely used process in the manufacturing industry, and it is a valuable tool for improving the wear resistance, fatigue strength, and impact strength of metal parts. Here are some of the disadvantages of flame hardening: It is a relatively imprecise process, and it can be difficult to control the depth of the hardened layer. It can produce distortion in the part, especially if the part is not properly clamped during the hardening process. It can be difficult to harden complex shapes. Overall, flame hardening is a versatile and cost-effective process for hardening the surface of metal parts. It is well-suited for high-volume production, but it is important to be aware of the potential disadvantages of the process, such as distortion and difficulty in hardening complex shapes.

Here are some questions that an interviewer might ask a candidate for a BIW fixture design and detailing position:

1) What is BIW?
2) What is 3-2-1- principle? Please explain.
3) What is PLP or RPS ? Please explain
4) Why shimming is used in BIW fixture?
5) Why 2 way shimming is used?
6) What is Mylar? or What is Rest block or Clamp block? Explain.

7) What is Riser? Is it gascut or welded structure?

8) Why dowels are used in BIW?
9) What is tolerance on dowel?
10) What is the general thickness of Mylar?

11) Do you need to do hardening for Mylar? Which hardening process?
12) What is a 4 way or 2-way location?

13) What is the difference between a round pin and a diamond pin?

14) What will be the tolerance on the location pin?

15) What is the thickness of the shims used below mylars?

17) Why Rough locators are used in BIW fixtures?

18) What is the purpose of a rough locator?

19) What should be the location pin size if I have A class panel hole of dia 10 and hole tol. is 0.1?

20) Which screws are better Allen screw or the hexagon head?

21) How much should be the depth of the thread if I use M8 tapping to mount mylar on the riser?

22) What is J /I riser? What is mfg .process? What is its thickness?

23) What will be min . height for location pin-straight portion for the panel location?

24) What will be the hardness of the location pin? What will be the hardening process?

25) What is a clamping scheme?

26) What is the Spot Welding process?

27) What is MIG?

28) What is the nugget diameter?
29) What should be the distance between two spots?
30) What should be min? flange width for welding of 2 panels?
31) How many panels can be spot welded together 2,3 or 4 panels at a time?
32) What should be the thickness ratio for welding 2 or 3 panels?
33) Can we weld 0.5 mm thick with 2mm?
34) What is cycle time?
35) What is takt time?
36) How much time it takes to weld one spot?
37) What is the weld sequence?
38) How much current needed to do spot weld?
39) What is C or X or Y gun?
40) What is IT or Non-IT Gun?
41) What is the diameter of the welding electrode?
42) How weld strength is checked? What are the different tests?
44) What is the general diameter of the electrode?
45) What is the material of the electrode?
46) After how many spots electrode has to be changed?
47) What is tip dressing?
48) How many times I can use the main PLP location hole?
49) Why I need a flanged hole?
50) What is the panel inspection fixture? Why it is necessary?

51) Do you have any idea about the welding inspection fixture?
52) What is the working height of the manual welding fixture?
55) What is a proximity sensor? Why it is used?
56) What is NAAMS Standard?
57) What will be tolerance on mylar block if it fitted on Riser? Clear, tight or interference fit
58) Why water is used in spot welding gun?
59) Can we do aluminum panel welding?
60) What is roller hemming? Where it is used?
61) How hemming is done?
62) What should be the height of the panel for roller hemming?
63) How many steps followed for roller hemming?
64) How much height we should have at the corner of the door?
65) Why sealant used in BIW?
66) What is the difference between the coated sheet and non coated sheet?
67) Which panel needed max current coated or non coated?
68) What is puddle welding?
69) What is MIG welding? Is it used in car BIW?
70) How Mylars are checked?
71) What is the purpose of CMM machine in BIW?
72) What is FARO?
73) What is the accuracy of FARO Arm?
74) What is the general speed of roller hemming robot ( in terms of mm/min)
75) What is toggle clamp?
76) Why toggle clamp used in the BIW welding fixture?
77) Why toggle clamp pivot point and PLP should be in one line?
78) What is gripper?
77) Why grippers are used?
79) Can I mount weld gun and gripper on the same robot?
80) What are light curtains?
81) What is gantry?
82) What is the lift and carry mechanism?
83) What is the shuttle system?
84) What is the framing station?
85) What is Geo Station?
86) What is respot station?
87) What is the chisel test?
88) What is S-Grun material?
89) What is Teflon material?
90) Why stress relieving has to be done after welding?
91) Why dowel holes are made on base plates?
92) What is blackodising ? Why it is done?
93) Do you apply pressure on a panel during toggle clamping?
94) Why BIW tools are designed for Left-Hand side only? For Chassis component
95) What are carlines?
96) Where is car origin? X=0,Y=0,Z=0
97) Why one round hole and one slot strategy followed for deciding PLP of the panel?
98) Is it possible to use Hole -Hole strategy? Who is using it now?
99) Can we weld aluminum with steel?
100) What is water jet cutting? Is it used in BIW fixturing?
101) What is gas cutting? Can I cut St 52-3 mat. 200thk by gas cutting?
102) Have you used laser cutting for a 10mm thk plate?

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