TERM PAPER ON

MANUFACTURE OF AUTOMOBILE

SUBMITTED TO: AMITY SCHOOL OF ENGINEERING AND TECHNOLOGY

Guided By: Dr.Pinkey Chauhan Amity Institution of Applied Sciences ASET, Noida

Submitted By: Name: Sandeep A2305412100

Enroll no. :

Roll no. : 100 Class: B. Tech. MAE2Y (2012-16)

AMITY UNIVERSITY, UTTAR PRADESH

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ACKNOWLEDGEMENT
Ability is what you are capable of doing. Motivation determines what you do. Attitude determine how well you do it -Lou Holtz

These valuable words said by Lou Holtz, author and a motivational speaker greatly inspired me to go beyond my capabilities and explore the world of automobiles and also try to figure out the new possibilities in the automobile industry. It was only because of the motivation of my faculty guide Dr.Pinkey Chauhan, i was able to undertake such a topic for my thesis. This topic wasnt easy to be undertaken but all thanks to my faculty guide for her kind guidance and timely help. I experienced many tough situations while dealing with the topic as it was a new task that i havent performed earlier, but in the pursuit of learning something new, i proceeded with the positive attitude and have tried my level best to bring out something great. I would also acknowledge here the efforts of my peers, who were kind enough to review, criticize and give inputs for the betterment of the thesis. Furthermore, i am thankful to my parents who supplied me with all the resources necessary for thesis and whose dotted love for us and absolute belief in our hard work, encouraging us even more to achieve our task. At last but not the least, i am grateful to Amity University, for giving me such a remarkable opportunity to seek for, explore and learn what the world has to offer us.

THANK YOU, Sandeep

CERTIFICATE

This is to certify that Mr. Sandeep student of B. Tech. in Mechanical and Automation Engineering Department have carried out the work presented in the project of the Term paper entitle Manufacture of Automobile as a part of First Year program of Bachelor of Technology in Mechanical and Automation Engineering from Amity School of Engineering and Technology, Amity University, Noida, Uttar Pradesh under my supervision.

Dr.Pinkey Chauhan Department of Applied Science ASET, Noida

INDEX

S.NO 1. 2. 3.

TOPIC ABSTRACT INTRODUCTION OVERVIEW OF MANUFACTURING PROCESS

PAGE NO. 5 6 7

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

STAMPING PROCESS PAINT PROCESS NEW WELDING TECHNIQUES POWRE-TRAIN ASSEMBLY LINE INSPECTIONS HYBRID CARS DISCUSSION APPENDIX CONCLUSION BIBLIOGRAPH

8 9 11 13 15 17 18 19 21 22 23

ABSTRACT

As the time progresses, so the technology also advances. Automobile sector is one of the most technologically advanced areas today. New techniques are being accepted/invented to make a more reliable and efficient automobile. Earlier manufacturing process involved setting up assembly stands on which the whole vehicle was built, usually by a single assembler who fit an entire section of the car together in one place. This person performed the same activity over and over at his stationary assembly stand this took many hours to manufacture an automobile. With the advancement in the technology the moving assembly line was introduced, in which a conveyor moved the vehicle past a stationary assembler. This reduced the time in manufacturing to a considerable amount and brought a revolution in automobile industry. The manufacturing workload is divided into sub-stations so called as shops such as paint shop, weld shop etc. Automobile companies are researching on new materials that can be used for making body panels, two of them being magnesium alloy and compacted graphite cast iron (CGI) to make vehicles lighter and efficient. Earlier in manufacturing process of automobiles most of the effort was put by skilled human labour which is now significantly being replaced by well designed machines and robots. However, with great emphasis on increasing the efficiency and reducing the cost of the vehicle, manufacturers have began to look for new techniques such as SMED which is turning out to be beneficial for both the manufacturer and costumer. The scrap parts / materials after the manufacture of auto bodies are recycled by various techniques. In this term paper we have tried to figure out in the best possible and compact manner about the various trends in the manufacturing process and the new advancements in this process which have brought in the revolution in the automobile industry.

INTRODUCTION An Automobile, Auto car, motor car is a wheeled motor vehicle used for transporting of passengers, which also carries its own engine or the motor. Automobiles are primarily designed to run on the roads, to have seating for one to eight people, these generally are made to have four wheels, and to be constructed principally for the transporting of the peoples rather than for the goods. HISTORY OF AUTOMOBILE Nicolas-Joseph Cugnot is credited with manufacture of the first full-scale, self-propelled mechanical automobile which was a steam powered tricycle in 1769. However his invention was accompanied with problems of water supply and maintaining of the steam pressure. Although many inventors including Richard Trevithick, French inventor Gustavo Trouv(demonstrated three-wheeled automobile powered by electricity),Gottlieb Daimler etc,were working on the problem ,it was Karl Benz acknowledged as inventor of modern automobile who in 1885 came up with four stroke internal combustion engine vehicle (Motorwagen). The first factory-made car in the world was produced by Czech company MANUFACTURING OF AUTOMOBILES With the advancement in the technology the many new inventions were made in the field of automobiles to comfort the customers the automobiles manufacturers came up with the efficient and affordable designs. The process of the planning, manufacture and distributing cars is lengthy and detailed one. From the first inspiration to drive away a lot of thought, effort and money go into producing the worlds most famous, unique popular cars.Manufacturing of automobiles and auto components involves certain process such as casting, forging, painting and electroplating.

OVERVIEW OF MANUFACTURING PROCESS

STAMPING

INSPECTIONS

WELDING TECHNIQUES

ASSEMBLY LINE

VEHICLE PAINT PROCESS

ENGINE MACHINING

SATAMPING PROCESS
This is the first step in manufacturing of automobiles. However, normally the processes used extensively are blanking, drawing, piercing, forming, notching, trimming, hemming, etc. the main raw material i.e. steel is supplied here and various operations are performed on it by dies. The various processes performed here prepares the body panels, which are used to make the body of a car. The steel supplied here is in form of coils.

Blanking Blanking cuts the periphery of a stamped part in one operation. This operation is similar to perforating except the slug is saved as the finished product. Note that the burr is up when blanking down. This burr is in the opposite direction of all other holes or notches within the part. The only exception to this condition is when the part is blanked out in the upward direction as in a compound blank die.

Piercing Piercing makes a hole without removing a slug. A sharp or pointed punch tears open a hole, leaving a ragged edge that has been formed down. A food grater is a good example of what pierced holes look like in a finished product.

Notching Notching produces a partial hole in the edge of the part.Cutting on one side of the punch generates lateral deflection of the punch point. For this reason, notching punches typically require a heel, with little or no clearance, opposite the cutting edge. The heel of the punch picks up on the matrix before the cutting edge contacts the part material. A small radius on the heel prevents it from clipping the top edge of the matrix, which could possibly break the punch and matrix

PAINT PROCESS
The vehicle body is generally pressed and welded and transported to a pre-clean area. Here, high pressure water spray jets are directed at the body with the purpose of cleaning off dirt and debris from previous processes. This detritus can take many forms ranging from parts of components used in the production process, to operator refuse or items of clothing such as gloves. The vehicle is then transferred to the alkali dip rinse. The bodies are circulated through a series of dip tanks, which
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essentially degrease and clean the metal work. Each body is totally submerged in the caustic rinse, ensuring that no section is left untreated. Afterwards, the alkali dip excess fluid is drained from the vehicle body before the rinsing operation. During the dip rinse the full body of the vehicle is submerged in de-ionized water. This, like so many stages in the production process, is another cleaning operation. Next, the vehicle body goes onto the conditional spray. Spray pumps direct de-ionized water onto the vehicle body, generally at ambient temperatures before the phosphate operation. During the phosphate operation the body is completely submerged in a phosphate liquid which chemically etches the metal work and provides a layer of crystal on the surface of the steel. This enables the paint to bite into the metal work for good adhesion. Occasionally, some plants opt for a partial phosphate dip, instead of a full phosphate dip, which is complemented by spray jets directing phosphate solution onto the roof of the vehicle. It is not uncommon to see many re-iterations of the same process, i.e. cleaning, etching, rinsing etc. This is a safeguard against wasted efforts further along the production line. The care and attention required in the pre-treatment makes this one of the most critical elements in the plant in obtaining a good paint finish. The phosphate system is sometimes referred to as "the bond". This is the part of the plant which bonds the paint to the steel body frame. If the body is going into storage, the hot blower is commonly encountered. From the phosphate operation, the body of the vehicle is transported to the preparation deck and then onto the ELPO (Electro Coat Paint Operation), commonly referred to as the E-Coat, a water based painting operation. During the ELPO process, the
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body is immersed or dipped into electro-coat paint. The whole body is charged with electricity (similar to a plating process). The paint sticks to the body as the body is charged, as it effectively becomes a cathode whilst the paint becomes an anode. Lastly the vehicle body goes through a DI-spray and DI-dip which is effectively a cleaning spray operation, then into an oven for approximately 20 minutes.

NEW WELDING TECHNIQUES:

Welding has been one of the most important steps in automobile manufacturing. Different body panels are joined here to make a outline of an automobile. But in recent times robots are significantly being used in manufacturing process.

Role of robots
Good design, furious production cycles, and weight and cost reduction all are issues that drive automotive manufacturing today.vehicle Manufacturers cannot afford to sit still while consumers' tastes change. Robotic welding plays a key role in enabling car companies to keep pace with demand for new, more technologically advanced, higher quality product. It's the repeatability of the robot that's prized today, with weld requirements down to1 to 2 mm. One means to keep costs down is to increase the density of weld guns per station to reduce the floor space and hence the overall cost. Advancements in both AC and DC weld controllers and the coming of servo gun technology will all help expand welding applications for difficult materials, such as thin or exotic metals.

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At the forefront of this new technology are servo guns, which are controlled by electronic motors rather than pneumatic or hydraulic cylinders and can be more completely integrated and controlled through the robot interface software. More than just servo weld guns, customers are calling for "the design of modular weld guns to include common parts for a variety of weld gun designs, allowing for continuous improvements to servo and hydraulic weld head designs.Moving to aluminum guns eliminates a lot of variations, unknowns, and manufacturing time. Of course, it also makes it lighter, too, allowing the gun to get from spot to spot faster.

Motoman has introduced manipulators specifically for spot welding - the ES165 and ES200, with 165- and 200-kg payloads, respectively.These robots have utilities (air, water, and power) routed in cable harnesses through the arm and out to the robot wrist. The standard cable harness supports either servo-controlled.The internal harness eliminates the need for supports and swivels associated with external "dress-out" packages.

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POWER TRAIN
An engine block is the core of the engine which houses nearly all of the components required for the engine to function properly. The block is typically arranged in a V, inline, or 4 horizontally-opposed (also referred to as flat) configuration and the number of cylinders range from either 3 to as much as 16. Because engine blocks are a critical component of an engine, it must satisfy a number of functional requirements. These requirements include lasting the life of the vehicle, housing internal moving parts and fluids, ease of service and maintenance, and withstand pressures created by the combustion process.

Properties of the material required

In order for an engine block to meet the functional requirements , the engineering materials used to manufacture the product must possess high strength, modulus of elasticity, abrasion resistance, and corrosion resistance. High strength is a particular concern in diesel engines, since compression ratios are normally 17.0:1 or higher (compared to about 10.0:1 for conventional engines). The material should also have a low density, thermal expansion (to resist expanding under high operating temperatures), and thermal conductivity (to prevent failure under high temperatures). Good machinability and castability of the metal alloy are also important factors in selecting the proper material, as the harder it is to machine the product, the higher the costs of manufacturing. In addition to the previously mentioned properties, the alloys must possess good vibration damping to absorb the shuddering of the moving parts.

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Materials for making engine block

Based on the functional requirements of the cylinder block and the material properties required to meet the functional requirements, industries have used cast iron and aluminum alloys to manufacture the blocks. Cast iron alloys are used because of the combination of good mechanical properties, low cost, and availability. Certain aluminum alloys combine the characteristics of iron alloys with low weight, thereby making the material more attractive to manufacturers who are seeking a competitive edge. Compacted graphite cast iron is lighter and stronger than gray cast iron, making the alloy a more attractive alternative to the latter in the production of cylinder blocks, particularly in diesel engines. Magnesium alloys, which were previously unsuited for use as an engine block material, have the advantage of being the lightest of all the mentioned metals, yet still retains the required strength demanded by a block. After the formation of cylinder block various other parts such as pistons, cranks etc are attached to the engine block to make an engine. Future technology: Magnesium and compacted graphite cast iron alloys are being used that reduces 57% weight of an engine block thus making it more efficient and light. These are AMC-SC1 and CGI.

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ASSEMBLY LINE
An assembly line is a manufacturing process in which parts (usually interchangeable parts) are added to a product in a sequential manner to create a finished product much faster than with handcrafting-type methods. Assembly lines are designed for the sequential organization of workers, tools or machines, and parts. The motion of workers is minimized to the extent possible. All parts or assemblies are handled either by conveyors or motorized vehicles such as lifting machines, with no manual trucking. Heavy lifting is done by machines such as overhead cranes. Each worker typically performs one simple operation. According to Ford: The principles of assembly are these: (1) Place the tools and the men in the sequence of the operation so that each component part shall travel the least possible distance while in the process of finishing. (2) Use work slides or some other form of carrier so that when a workman completes his operation, he drops the part always in the same placewhich place must always be the most convenient place to his handand if possible have gravity carry the part to the next workman for his operation. (3) Use sliding assembling lines by which the parts to be assembled are delivered at convenient distances.

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Methods adopted by BMW in assembly line

The giant manufacturing company BMW follows the following steps in a sequential manner: All computers and controls in Assembly are linked together by nearly 16,000 miles of communications cables. s position the car so associates can install parts on the underbody.

assembly line. er trim pieces are installed.

same car body.

heated to about 100 degrees, which makes the thick wiring harness pieces more flexible and easier to install.

car body with clips and wire ties. r is on every hood. This device helps track the car throughout the Assembly process.

parts are assembled here. wertrain to the Marriage area.

car body is lowered.

(radiator, brake, power steering, coolant, gas) are added here.

start-up. gine and transmission its first good test.

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INSPECTIONS
It is the most important step in the manufacture of the automobile as here the automobile and its components are checked in for any defects. Each of the manufactured vehicles needs to undergo the quality check before being dispatched for the supply to the consumers. As most of the components to be installed in the vehicle are being supplied by outside suppliers hence for the assurance of the safety. These companies at their production end undergo safety test Statistical Process Control for their approval of the defect free products. Formerly the quality control was seen as final inspection process that sought to discover the defects only after the vehicle is built. In contrast, today quality is seen as a process built right into the design of the vehicle as well as the assembly process. In this way assembly operators can stop the conveyors if workers find a defect. Corrections can then be made or supplies checked to determine whether the entire batch of component is bad. Vehicle recalls are costly and the manufacturers do everything possible to ensure the integrity of their product before it is shipped to the customers. After the vehicle is assembled a validation process is conducted at the end of the assembly line to verify quality audits from the various inspection points throughout the assembly process. The final audit test for the properly fitting panels, dynamics, functioning electrical components and engine, chassis etc. In many assembly plants the vehicles are periodically pulled from the audit line and given full functional tests. The vehicles are then let out for the supplies to the consumers.

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THE FUTURE OF AUTOMOBILES: HYBRID CARS

Despite their increased fuel efficiency and potential for eco-friendly, green driving, hybrid vehicles are manufactured in much the same way other cars are. As with the build-process of most cars, the typical hybrid is put together on an assembly line according to a carefully choreographed series of steps. Conveyor belts shuttle the parts along and elevators move parts into place. Both human workers and machines are involved in the process. The main difference in the creation of these fuelefficient vehicles is in the batteries. Hybrid batteries are large, rechargeable and they take up a considerable amount of space. They're made by specialty battery companies, like Panasonic and Sanyo, chiefly located in Japan. Most current hybrids use nickel metal hydride (NiMH) batteries. However, some of the newest hybrids use the more advanced lithium-ion (Li-ion) batteries. To make a lithium-ion battery, a lithium ingot is extruded under pressure into a sheet that's just .01 inches (0.254 millimeters) wide. Machinery is then used to wind these sheets into tightly coiled cells. These wound-up sheets are baked at a high temperature and molten metal is sprayed onto the sheets by automated equipment -- a process known as metalizing. Several metalized battery cells are then stacked together in a module. There are certain misconceptions about hybrid car manufacturing. One is that the amount of carbon dioxide released in the manufacture of a hybrid car, such as the Toyota Prius, is greater than the amount saved by driving one. Many experts have debunked this idea, yet it persists. According to Toyota's own figures, a Prius only has to be driven for about 13,000 miles (20,921 kilometers) for the CO2 savings to outweigh the manufacturing costs. It has also been suggested that the sheer

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distance the nickel used in the manufacture of the Prius' NiMH batteries travels before it reaches the factory causes more energy to be burned than would be burned by driving a Hummer instead of a Prius. However, analysts have shown that this idea is based on faulty assumptions. The Prius saves more energy than the manufacturing process uses.

DISCUSSION: ENVIRONMENTAL ISSUES

Paint is the biggest environmental problem that car factories face. Dealing with this takes up major proportion of environmental expenditure. Fixed capital costs are high for emissions and waste treatment equipment. Equally, operating costs are substantial due to high energy and material use as well as material waste treatment and disposal. All this adds up to major difficulties in balancing costs in the paint plant while meeting regulatory and production expectations. The three key areas of environmental concern are as follows: Air emissions Paint processes are currently subject to local authority regulation and visits from these authorities to ensure compliance. VOC (volatile organic compounds) emissions are the main concern in this respect, due to their potential to cause respiratory problems particularly for local communities. Thermal oxidizers are used to burn off excess VOCs released and reduce the amount entering the atmosphere. The new European VOC Directive will bring down
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current emissions limits requiring either more capital equipment for abatement or alternative low solvent paints such as high solids, water-based paints or even powder coats. Waste The primary source of hazardous waste from automotive plants is again from paint processes. Although much material is recovered, this waste is typically around 25 percent of a plants total hazardous waste by weight. The solvents and heavy metals left in residues mean that it is classified as hazardous through European law. Most of this results from cleaning processes in the paint plant. Energy Curing ovens use vast amounts of energy for the paint to go off in an acceptable time. The more speed required, the higher the energy use. This is further exacerbated by waterbased paint requiring more time in curing ovens than solvent-based paint. Powder coats also require more use of ovens due to the thickness of coats for curing.

Possible Solution for the problem

Powder coat systems remove the impact of VOC emissions completely and are 100 percent Material recyclable. Any excess paint can be literally 'swept off the floor' and re-used. This Means waste levels are also very low compared with water-based paints which have significant Paint sludge and waste water outputs. However, high energy curing results as trade-off from This. The environmental consequences of more flexible and lean production are bound to increase when shortened lead-times and smaller batch sizes are required.

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CONCLUSION
The learning experience of vehicle manufacturing process was good. I learnt whole new things about manufacturing of automobiles starting from the blanking process to vehicle inspections that I was unaware of till now. Each process of vehicle manufacturing is complex but interesting also. It was good to see that both humans and robots working together. I learnt about the materials, their use and their property for using them. Earlier, I had no knowledge about the manufacturing of automobiles/cars but through this work I gained a lot of information about automobiles. Even, I didnt know that which material is used to make the panels but now I know that these are steel coils that are used to make the outside panels. The welded panels together are quiet given a strange name i.e. BIW (body in white) that has no color at all. The most amazing thing was the SMED that changed the dies used for cutting sheets within in a single digit minute (0-9), which made the process faster and economical. Modern fuels are being used instead of petrol and diesel; these fuels are ethanol-flexible fuel and natural gas which have lesser impact on the environment. Hybrid vehicles are nowadays a topic for completion among the companies. The IC engines are thought to be replaced by electric motors, which would run on chargeable batteries but because of high weights batteries researches are being done to make the vehicles run by electric motors. Designers are also looking for replacement of iron/aluminum alloy, which are used to make engine blocks. Magnesium alloy AMC-SC1 and CGI. While working on this term paper, it was a very good experience and learning one also.

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BIBLIOGRAPHY
Edited volumes Clarke (2005), Automobile production systems and standardization, physica Verlag. 3-79081578-0, Heidelberg Hitomi, K. (1996). Manufacturing systems engineering, 0-484-0323-x, London MA-AL Jader, N, Wylie, JD Chullen, Spot welding process for automotive industry Other websites Automobile, [HTML Document]. Retrieved from World Wide Web http://www.wikipedia.com/automobile Assembly line-BMW, [HTML Document]. Retrieved from World Wide Web http://www.BMWusfactory.com/assemblyline Metal fabrication and stamping tools. [HTML document].retrieved from World Wide Web http://www.dayton.com/stamping Manufacturing process, [HTML document]. Retrieved from World Wide Web http://www.siemens.com/manufacturingpocess Electronic books Car manufacturing process, Maruti Suzuki India Limited [HTML document]. Retrieved from the World Wide Web, http://www.tmpclubindia.org

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APPENDIX
AMC-SCI is an alloy made by Australian Magnesium Corporation and SC1 stands for Sand Cast. Percentage of raw materials used

Comparison of two engines:

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