THE AUTOMOTIVE BODY MANUFACTURING SYSTEMS AND PROCESSES -- Contents -- Preface -- Foreword -- Acknowledgments -- Abbreviations -- 1: Introduction -- 1.1 Anatomy of a Vehicle, Vehicle Functionality and Components -- 1.2 Vehicle Manufacturing: An Overview -- 1.2.1 Basics of the Assembly Processes -- 1.2.2 Basics of the Power-train Processes -- 1.3 Conclusion -- Exercises -- 2: Stamping and Metal Forming Processes -- 2.1 Formability Science of Automotive Sheet Panels: An Overview -- 2.1.1 Stamping Modes and Metal Flow -- 2.1.2 Material Properties and their Formability -- 2.1.3 Formability Measures -- 2.1.4 Circle Grid Analysis (CGA) and the Forming Limit Diagram (FLD) -- 2.2 Automotive Materials -- 2.2.1 Automotive Steel Grades -- Traditional Steel Grades -- 2.2.2 Automotive Steel Grades: High Strength and Advanced (Ultra) -- 2.2.3 Stamping Aluminum Sheet Panels -- 2.3 Automotive Stamping Presses and Dies -- 2.3.1 Automotive Dies -- 2.3.2 Die Operation and Tooling -- 2.3.2.1 The Blank Holder -- 2.3.2.2 Draw Beads -- 2.3.2.3 Blanking and Shearing Dies -- 2.3.2.4 Bending -- 2.3.2.5 Deep Drawing -- 2.3.2.6 Coatings and Lubrications -- 2.4 Tailor Welded Blanks and their Stamping -- 2.5 Advances in Metal Forming -- 2.5.1 Hydro-forming and Extrusions -- 2.5.2 Industrial Origami: Metal Folding-Based Forming -- 2.5.3 Super-plastic Forming -- 2.5.4 Flexible Stamping Procedures -- 2.6 Stampings Dimensional Approval Process -- 2.7 Stamping Process Costing -- 2.7.1 Case I: The Stamping Process -- 2.7.1.1 Detailed Cost Analysis -- 2.7.2 Case II : Tailor-Welded Door Inner Cost -- Exercises -- 3: Automotive Joining -- 3.1 Introduction -- 3.2 Fusion Welding Operations -- 3.2.1 Basics of Arc Fusion Welding and its Types -- 3.2.2 Metal Inert Gas MIG Welding Processes -- 3.2.3 Automotive TIG Welding Processes -- 3.2.4 Automotive Resistance Welding Processes.

3.2.4.1 Surface Conditions and Their Effect on Resistance Welding -- 3.2.4.2 Basics of Spot Welding, Lobes and Resistance Curves -- 3.3 Robotic Fusion-Welding Operations -- 3.3.1 Robotic Spot Welders -- 3.4 Adhesive Bonding -- 3.4.1 Basics of Adhesive Material Selection -- 3.4.2 Basics of the Adhesion Theory and Adhesives Testing -- 3.5 Welding and Dimensional Conformance -- 3.6 Advances in Automotive Welding -- 3.6.1 Friction Stir Welding (FSW) -- 3.6.2 Laser Welding -- 3.6.3 Weld Bonding -- 3.7 The Automotive Joining Costing -- 3.7.1 Joining an Automotive Frame -- 3.7.2 Sub-assembling Automotive Doors -- Exercises -- 4: Automotive Painting -- 4.1 Introduction -- 4.2 Immersion Coating Processes -- 4.2.1 Cleaning -- 4.2.2 Rinsing -- 4.2.3 Conversion and Phosphate Baths -- 4.2.3.1 Phosphating Aluminum -- 4.2.4 E-Coating Baths and their Operations -- 4.3 Paint Curing Processes, and Balancing -- 4.4 Under-Body Sealant, PVC and Wax Applications -- 4.5 Painting Spray Booths Operations -- 4.5.1 Spray Paint Applicators -- 4.5.2 Painting Booth Conditioning, Waterborne, Solvent-borne and Powder-coating Systems -- 4.5.2.1 Waterborne Paint -- 4.5.2.2 Powder Coating -- 4.5.3 Paint Calculations -- 4.6 Material Handling Systems Inside the Painting Area -- 4.7 Painting Robotics -- 4.8 Paint Quality Measurements -- 4.8.1 Paint Defects and Theory -- 4.8.1.1 Theoretical Background -- Exercises -- 5: Final Assembly -- 5.1 Basics of Final Assembly Operations -- 5.1.1 Installation of the Trim Assembly -- 5.1.2 Installation of the Chassis -- 5.1.3 Final Assembly and Testing Area -- 5.2 Ergonomics of the Final Assembly Area -- 5.3 Mechanical Fastening and Bolting -- Exercises -- 6: Ecology of Automotive Manufacturing -- 6.1 Introduction of Automotive Manufacturing Ecology -- 6.2 Energy Consumption and Accounting -- 6.2.1 The EPA Energy Model.

6.2.2 Specific Energy Requirements from the EPI Model -- 6.2.3 Panel-Forming Energy -- 6.2.4 Hybridized Structures Selection and Energy Implications -- 6.2.5 Proposed Approach versus Previous Models -- 6.2.6 Conclusion and Comments on Specific Energy Modeling -- 6.3 The Automotive Materials' Ecological Impact -- 6.4 The Painting Process Ecology -- 6.5 Ecology of the Automobile -- 7: Static Aspects of the Automotive Manufacturing Processes -- 7.1 Introduction -- 7.2 Layout Strategies -- 7.3 Process-oriented Layout -- 7.4 Cell-based Layout Design -- 7.5 Product-based Layout -- 7.6 Lean Manufacturing Tools for Layout Design and Optimization -- 7.7 Locational Strategies -- 7.7.1 Locational Strategies Tools -- Exercises -- 8: Operational Aspects of the Automotive Manufacturing Processes -- 8.1 Introduction -- 8.2 Aggregate Production Planning -- 8.3 Master Production Scheduling (MPS) -- 8.4 Material Requirement Planning (MRP) -- 8.5 Production Line Control and Management Style -- 8.5.1 Lean Manufacturing Management of Workers -- 8.6 Selection and Management of Suppliers -- 8.6.1 Selection and Management Process -- 8.7 An Overview of the Automotive Quality Tools -- 8.7.1 The Production Part Approval Process (PPAP) -- 8.7.2 The Advanced Product Quality Planning (APQP) -- 8.7.3 The Failure Mode and Effect Analysis (FMEA) -- Exercises -- References -- INDEX.