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E-raamat: Automotive Body Manufacturing Systems and Processes

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(Clemson University, USA)
  • Formaat: EPUB+DRM
  • Ilmumisaeg: 10-Feb-2011
  • Kirjastus: John Wiley & Sons Inc
  • Keel: eng
  • ISBN-13: 9781119990871
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Automotive Body Manufacturing Systems and ProcessesSuurem pilt
  • Formaat: EPUB+DRM
  • Ilmumisaeg: 10-Feb-2011
  • Kirjastus: John Wiley & Sons Inc
  • Keel: eng
  • ISBN-13: 9781119990871
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The Automotive Body Manufacturing Systems and Processes The Automotive Body Manufacturing Systems and Processes

A comprehensive and dedicated guide to automotive production lines, The Automotive Body Manufacturing Systems and Processes addresses automotive body processes from the stamping operations through to the final assembly activities. To begin, it discusses current metal forming practices, including stamping engineering, die development, and dimensional validation, and new innovations in metal forming, such as folding based forming, super-plastic, and hydro forming technologies. The first section also explains details of automotive spot welding (welding lobes), arc welding, and adhesive bonding, in addition to flexible fixturing systems and welding robotic cells. Guiding readers through each stage in the process of automotive painting, including the calculations needed to compute the number of applicators and paint consumption based on vehicle dimensions and demand, along with the final assembly and automotive mechanical fastening strategies, the books systematic coverage is unique.

The second module of the book focuses on the layout strategies of the automotive production line. A discussion of automotive aggregate planning and master production scheduling ensures that the reader is familiar with operational aspects. The book also reviews the energy emissions and expenditures of automotive production processes and proposes new technical solutions to reduce environmental impact.





Provides extensive technical coverage of automotive production processes, discussing flexible stamping, welding, and painting lines Gives complete information on automotive production costing as well as the supplier selection process Covers systems from the operational perspective, describing the aggregate and master production planning Details technical aspects of flexible automotive manufacturing lines Methodically discusses the layout and location strategies of automotive manufacturing systems to encompass the structural elements Features topic-related questions with answers on a companion website
Preface xi
Foreword xiii
Acknowledgments xv
List of abbreviations
xvii
1 Introduction
1(14)
1.1 Anatomy of a Vehicle, Vehicle Functionality and Components
1(1)
1.2 Vehicle Manufacturing: An Overview
2(9)
1.2.1 Basics of the Assembly Processes
4(3)
1.2.2 Basics of the Power-train Processes
7(4)
1.3 Conclusion
11(4)
Exercises
13(2)
2 Stamping and Metal Forming Processes
15(92)
2.1 Formability Science of Automotive Sheet Panels: An Overview
18(23)
2.1.1 Stamping Modes and Metal Flow
25(2)
2.1.2 Material Properties and their Formability
27(5)
2.1.3 Formability Measures
32(4)
2.1.4 Circle Grid Analysis (CGA) and the Forming Limit Diagram (FLD)
36(5)
2.2 Automotive Materials
41(20)
2.2.1 Automotive Steel Grades; Traditional Steel Grades
41(5)
2.2.2 Automotive Steel Grades: High Strength and Advanced (Ultra)
46(9)
2.2.3 Stamping Aluminum Sheet Panels
55(6)
2.3 Automotive Stamping Presses and Dies
61(13)
2.3.1 Automotive Dies
64(2)
2.3.2 Die Operation and Tooling
66(1)
2.3.2.1 The Blank Holder
67(1)
2.3.2.2 Draw Beads
67(1)
2.3.2.3 Blanking and Shearing Dies
67(4)
2.3.2.4 Bending
71(1)
2.3.2.5 Deep Drawing
72(1)
2.3.2.6 Coatings and Lubrications
72(2)
2.4 Tailor Welded Blanks and their Stamping
74(6)
2.5 Advances in Metal Forming
80(6)
2.5.1 Hydro-forming and Extrusions
80(3)
2.5.2 Industrial Origami: Metal Folding-Based Forming
83(2)
2.5.3 Super-plastic Forming
85(1)
2.5.4 Flexible Stamping Procedures
85(1)
2.6 Stampings Dimensional Approval Process
86(5)
2.7 Stamping Process Costing
91(16)
2.7.1 Case I: The Stamping Process
93(1)
2.7.1.1 Detailed Cost Analysis
93(5)
2.7.2 Case II Tailor-Welded Door Inner Cost
98(3)
Exercises
101(6)
3 Automotive Joining
107(70)
3.1 Introduction
107(1)
3.2 Fusion Welding Operations
107(27)
3.2.1 Basics of Arc Fusion Welding and its Types
108(3)
3.2.2 Metal Inert Gas MIG Welding Processes
111(6)
3.2.3 Automotive TIG Welding Processes
117(1)
3.2.4 Automotive Resistance Welding Processes
117(9)
3.2.4.1 Surface Conditions and Their Effect on Resistance Welding
126(3)
3.2.4.2 Basics of Spot Welding, Lobes and Resistance Curves
129(5)
3.3 Robotic Fusion-Welding Operations
134(10)
3.3.1 Robotic Spot Welders
140(4)
3.4 Adhesive Bonding
144(9)
3.4.1 Basics of Adhesive Material Selection
147(2)
3.4.2 Basics of the Adhesion Theory and Adhesives Testing
149(4)
3.5 Welding and Dimensional Conformance
153(1)
3.6 Advances in Automotive Welding
154(4)
3.6.1 Friction Stir Welding (FSW)
154(1)
3.6.2 Laser Welding
155(1)
3.6.3 Weld Bonding
156(2)
3.7 The Automotive Joining Costing
158(19)
3.7.1 Joining an Automotive Frame
158(10)
3.7.2 Sub-assembling Automotive Doors
168(4)
Exercises
172(5)
4 Automotive Painting
177(50)
4.1 Introduction
177(1)
4.2 Immersion Coating Processes
177(10)
4.2.7 Cleaning
179(1)
4.2.2 Rinsing
180(1)
4.2.3 Conversion and Phosphate Baths
181(3)
4.2.3.1 Phosphating Aluminum
184(1)
4.2.4 E-Coating Baths and their Operations
184(3)
4.3 Paint Curing Processes, and Balancing
187(5)
4.4 Under-Body Sealant, PVC and Wax Applications
192(2)
4.5 Painting Spray Booths Operations
194(15)
4.5.1 Spray Paint Applicators
196(4)
4.5.2 Painting Booth Conditioning, Waterborne, Solvent-borne and Powder-coating Systems
200(1)
4.5.2.1 Waterborne Paint
200(4)
4.5.2.2 Powder Coating
204(1)
4.5.3 Paint Calculations
205(4)
4.6 Material Handling Systems Inside the Painting Area
209(3)
4.7 Painting Robotics
212(2)
4.8 Paint Quality Measurements
214(13)
4.8.1 Paint Defects and Theory
216(1)
4.8.1.1 Theoretical Background
217(7)
Exercises
224(3)
5 Final Assembly
227(22)
5.1 Basics of Final Assembly Operations
227(4)
5.1.1 Installation of the Trim Assembly
228(1)
5.1.2 Installation of the Chassis
229(1)
5.1.3 Final Assembly and Testing Area
230(1)
5.2 Ergonomics of the Final Assembly Area
231(2)
5.3 Mechanical Fastening and Bolting
233(16)
Exercises
247(2)
6 Ecology of Automotive Manufacturing
249(40)
6.1 Introduction of Automotive Manufacturing Ecology
249(1)
6.2 Energy Consumption and Accounting
250(16)
6.2.1 The EPA Energy Model
252(1)
6.2.2 Specific Energy Requirements from the EPI Model
253(2)
6.2.3 Panel-Forming Energy
255(4)
6.2.4 Hybridized Structures Selection and Energy Implications
259(4)
6.2.5 Proposed Approach versus Previous Models
263(3)
6.2.6 Conclusion and Comments on Specific Energy Modeling
266(1)
6.3 The Automotive Materials' Ecological Impact
266(1)
6.4 The Painting Process Ecology
267(11)
6.5 Ecology of the Automobile
278(11)
7 Static Aspects of the Automotive Manufacturing Processes
289(30)
7.1 Introduction
289(1)
7.2 Layout Strategies
289(3)
7.3 Process-oriented Layout
292(3)
7.4 Cell-based Layout Design
295(2)
7.5 Product-based Layout
297(3)
7.6 Lean Manufacturing Tools for Layout Design and Optimization
300(3)
7.7 Locational Strategies
303(16)
7.7.1 Locational Strategies Tools
308(6)
Exercises
314(5)
8 Operational Aspects of the Automotive Manufacturing Processes
319(42)
8.1 Introduction
319(1)
8.2 Aggregate Production Planning
320(6)
8.3 Master Production Scheduling (MPS)
326(3)
8.4 Material Requirement Planning (MRP)
329(5)
8.5 Production Line Control and Management Style
334(6)
8.5.1 Lean Manufacturing Management of Workers
335(5)
8.6 Selection and Management of Suppliers
340(6)
8.6.1 Selection and Management Process
343(3)
8.7 An Overview of the Automotive Quality Tools
346(15)
8.7.1 The Production Part Approval Process (PPAP)
346(3)
8.7.2 The Advanced Product Quality Planning (APQP)
349(3)
8.7.3 The Failure Mode and Effect Analysis (FMEA)
352(5)
Exercises
357(4)
References 361(4)
Index 365
Mohammed A. Omar, Clemson University International Center for Automotive Research CU-ICAR, USA
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