Summer Internship, June-July2019

Submitted
By

Ritvik Andhavarapu

Internship
Done At

ITEN Softech Solutions Private Limited

Hyderabad, Telangana

KLEF
Green Fields, VADDESWARAM – 522 502
Guntur District, A.P., INDIA.
 Acknowledgment
It is a pleasure for me to express my gratitude to our honourable president
Sri.koneru Satyanarayana, for giving the opportunities and platform with facilities
for accomplishing the project based laboratory report.

I express the sincere gratitude to our principal Dr.K.Subbarao for his

administration towards academic growth.

I express the sincere gratitude to our Mechanical Head of the Department Dr.A.
Srinath for his administration towards our academic growth.

I express my sincere thanks to our project supervisor Mrs Uma and Mr.Vidyakar.
for their novel association of ideas, encouragement, appreciation and intellectual
zeal which motivated us to venture this project successfully.
Finally, it is pleased to acknowledge the indebtedness to all those who devoted
themselves directly or indirectly to make this project report success.
Table of Contents
About ITEN Softech Solutions Private Limited ....................................................................................................................... 4
Project identified for internship (Automotive BIW Fixtures) ................................................................................................. 5
BIW – Body in White ........................................................................................................................................................... 5
Tool utilized: ........................................................................................................................................................................... 6
Client:...................................................................................................................................................................................... 7
Fixtures ................................................................................................................................................................................... 7
Repeatability ....................................................................................................................................................................... 8
Interchangeability ............................................................................................................................................................... 8
Gripper ................................................................................................................................................................................ 9
Scope of work ..................................................................................................................................................................... 9
Types of units...................................................................................................................................................................... 9
PINS............................................................................................................................................................................... 10
Spanner unit ................................................................................................................................................................. 17
Degrees of freedom .......................................................................................................................................................... 25
12 degrees of freedom ................................................................................................................................................. 25
3-2-1 principle............................................................................................................................................................... 25
3-2-1 principle of clamping work piece ........................................................................................................................ 25
About ITEN Softech Solutions Private Limited
ITEN Softech is a leading Engineering Services provider located in Hyderabad. ITEN specializes in Civil and
Mechanical Engineering Services and supports its Clients in USA, Middle East and India. ITEN also supports
its clients by sending engineers/Designers to work at client locations on short and long duration
assignments. Their expert services would result in full-service, cost effective solutions with highest safety
standards. They serve clients in the Automotive, Oil & Gas, Refining, Chemical & other process plants, Infra
and Metals and Mining Industries. Their experience and project management processes enable us to be an
integral part of a project from its conception, through completion and every stage in between.

ITEN is a leading global Product Engineering, EPC Support & Consulting Company providing services that
include Preliminary Design/Bidding support, Design and Analysis including calculations, 3d modelling, GA
and Fabrication drawings, As-built updates etc. ITEN has successfully executed projects directly/ indirectly
for Automotive, Owners/GCs, Operators, EPC’s, Fabrication companies and Engineering consultants
globally.

To name a few of key clients: EBZ Systech, Tata Projects, Bilad Oman, Cleveland Bridge and Engineering,
Tiger Steel, Eversendai, Aker solutions, Petrofac, Worley Parsons, Valdel E&C, Metsco, FLSmidth, Mott
MacDonald, Simon India, Viladesign Engineering S.L., SPIE Controlec Engineering B.V., Samsung
Engineering, EBZ, CDC, Jacobs, Petron, L & T etc.
Project identified for internship (Automotive BIW Fixtures)

BIW – Body in White

In the Automotive Industry BIW (Body in White) is the common terminology used to
mention the car sheet metal welded structure (body shell).

In today's situation, automotive BIW is made of steel (various steel grade material -DP, DD,
HDP etc.) as well as made of aluminium alloy (e.g. AUDI A8)

Sub-assemblies like Under body, Body side Left Hand Side/ Right Hand Side, Front End, Roof
etc. gets welded together by various metal joining process e.g. resistance spot welding,
Laser welding, MIG welding to make welded metal shell (Without Door, Trunk-lid / Tailgate)
Fender, Bonnet Center) called Body in White.

Automotive car shell made before painting is called Body in White.

BIW joinery decides the exterior and interior look of any car.

All the Interior Parts(Commonly used in Automotive) e.g. Dashboard, Trim (Door Trim, Pillar
Trims, Roof liner, Seats are mounted on the BIW shell with the help of various brackets or
nuts mounted on the BIW.

Exterior (Commonly used term in car industry) components e.g. Front Bumper, Rear
Bumper, Fender LH/RH, Side Mirrors are mounted on the BIW shell with the help of various
brackets or mounting systems.

In car industry outer look defines the style. BIW sheet metal part shell defines overall car
style.
Tool utilized:

CATIA is a multi-platform software suite for computer-aided design, computer-aided

manufacturing, computer-aided engineering, PLM and 3D, developed by the French
company Dassault Systems. CATIA enables the creation of 3D parts, from 2D
sketches, composites, molded, forged or tooling parts up to the definition of mechanical
assemblies. The software provides advanced technologies for mechanical surfacing & BIW. It
provides tools to complete product definition, including functional tolerances as well
as kinematics definition. CATIA provides a wide range of applications for tooling design, for
both generic tooling and mould & die. In the case of Aerospace engineering an additional
module named the aerospace sheet metal design offers the user combine the capabilities of
generative sheet metal design and generative surface design.
Client:
The company where I was interned receives projects from the clients of EBZ(Engineering
Bausch & Ziege) present in Germany.

EBZ Group supporting automotive industry in the area of complete process chain of tooling and
production line installation. From engineering to manufacturing, the commissioning of
production lines and stamping dies, EBZ fulfils all requirements from a single source. With offices
around the globe, EBZ group is one of the leading service providers in the area of Body-In-White
production offering all related services starting with the development of the product to the
commissioning and optimization of a production line.

Fixtures
A fixture is a supporting device in the manufacturing industry. They are used for locating
position and support work. It is used for maintaining the repeatability and
interchangeability.

Repeatability
The ability to produce a part or component exactly the same in every single time is called
repeatability.

Interchangeability
The making of parts of machines with such tolerances that any part will properly function in
any kind of machines.
Gripper

A gripper enables holding, tightening, handling and releasing of an object it is a component

of an automated system which is attached to a robot or it can be part of a fixed automation
system

Scope of work
1)3D finish

2)2D

3)BOM (bill of materials)

Types of units
They are two types of units used in Fixtures and Grippers. They are

1.PIN UNIT

2.SPANNER UNIT
PINS
A pin unit is a located to car panel and restricted motion of panel , It can arrest the
DOF’S(degrees of freedom) of the panel. Typically the locating pins are used to lock a body
part in a position sufficiently accurate to execute a welding process. The body part is
constrained by a set of appropriately locating pin so total constrained by locating pin should
be fully constrained at all times to prevent any movement. Usually two locating pins are
enough to properly locate the body part on one plane. One of the pin is round ,and another
one is diamond shaped. This configuration will allow easier loading of body part. A single
clamping unit consists of the following parts.

 Pin
 L-Block
 Shim and Spacer
 Konsole (Riser)

3D Pin unit
Pin sketch

While making a 3d figure of any body the overall dimensioning must be given to the drawing
what we have done, so we need to mention the length, breadth, and it thickness and
remaining machining must be given to constrain the 3d object.
KONSOLE SKETCH (RISER)

The konsole holds all the parts in the pin unit of the fixture and it is connected to the base
plate. Konsole is used in pin unit and spanner unit. Many European companies use gas cut
riser made by cutting up to 50mm or 63mm thick steel plate.
2D unit of Pin (Orthographic views)

These are the orthographic projections of the pin unit present in the fixture done through
drafting process using CATIA tool and the image present below is the isometric view.
Isometric view of the pin unit:
Konsole detailing (Riser)
Flame cuts

When we give overall dimensions to the entire part in the drawing, then we can take part’s
or shape’s outline according to the given dimension from the 3D design. Flame cutting is
oxygen cutting in which the appropriate part of the material to be cut is raised to ignition
temperature by an oxy-fuel gas flame. Also known as oxy-fuel cutting, the process is used
for separating and shaping steel components.
BOM (bill of materials)

A bill of materials or product structure is a list of the raw materials, sub-assemblies,

intermediate assemblies, sub-components, parts, and the quantities of each needed
to manufacture an end product. A BOM may be used for communication between
manufacturing partners or confined to a single manufacturing plant.

Spanner unit
A tool with a shaped opening or jaws for gripping and turning a nut or bolt, when it comes
to the fixture it holds the car panel firmly and prevents the part from distortion while
carrying out to the spot welding operation.
3D unit of Spanner

Spanner unit (clamp unit):- Toggle clamps hold the car part firmly and prevent the part from
distortion while carrying out the spot welding operation. A single clamping unit consists of
the following parts.

 NC(numerical control, finger,Mylor)

 L-Block
 Shim and Spacer
 Konsole (Riser)
Druckstueck (NC)
It is the pressure giving NC(Numerical Control) present in the spanner which helps in holding
the car panel from the above.NC is called as Finger. Finger is a movable part which is used to
hold car part from top against backup and they are usually mounted on the clamp arm.
Auflage (NC)
It is the pressure receiving NC present in the spanner which helps holding the car panel from
the below. NC is called as Finger. Finger is a movable part which is used to hold car part
from top against backup and they are usually mounted on the clamp arm.
2D detailing of NC
Orthographic views of Spanner unit

These are the orthographic projections of the spanner and NC’s which is being taken from
the 3d object with overall dimensioning by drafting.
Isometric view of spanner
Flame cut

These are the flame cut of the NC’s and the spanner present in the above images.
Degrees of freedom

The number of independent ways by which a dynamic system can move, without violating

any constraint imposed on it, is called number of degrees of freedom. In other words, the

number of degrees of freedom can be defined as the minimum number of independent

coordinates that can specify the position of the system completely.

12 degrees of freedom

The degrees of freedom defines capability of body to move. Consider rectangular box, in

space the box is capable of moving in 12 directions(6 rotational and 6 axial). Each direction

of movement is counted as one degree of freedom in which a body in space has 12 degrees

of freedom

3-2-1 principle

Degree of freedom is defined as number of independent motions a body has.

3-2-1 principle of clamping work piece

i) 3pin

3 pins are used at bottom, it will restrict 4 rotational motions (x,y axis) and 1 translational

motion(-z direction).

ii) 2 pin

It will restrict 2 rotational motion (z axis) and 1 translational motion in (x direction).

iii) 1 pin

it will restrict 1 translational motion(y axis) and pin 3-2-1 combined will restrict 9 motion

and the remaining 3 motion is used to set workpiece at desired location and can be

restricted by clamp.