International University for Science & Technology

College of Engineering and Technology

Name : abd alkader almoghrebe

201620096

How the car is manufactured ?

Body Shop .I
Start with: unpainted individual formed sheet metal components
Finish with: an assembled car body,

1. underbody components, such as the floor pan and the motor component are
built up as sub assemblies. This is accomplished by taking individual sheet metal
components of varying sizes, fixturing them into a precise location and then RSW
(resistance spot welding) them into their final location. Here's the starting point:

2. finished subassemblies are assembled and added to the floor pan and motor
compartment. At the beginning a vehicle body starts flat, additional assembles
add some length, but also all the components that give a vehicle body height,
things like the firewall separating the motor from the passenger compartment
and the waterfall section between the backseat and the trunk.

3. at this point you have the rough shape of a car, but still lack the external body
panels that make it look like the final product, lack a roof, and have none of the
swing metal parts: doors, hood, deck lid (what you call a trunk/ boot in an
automotive factory)

4. In one of the more complex operations in the body shop the body sides are
placed onto the vehicle. This is typically the largest single piece of sheet metal
used in a vehicle.
5. Roof time. A roof panel is placed on top of the sheet metal layer cake that
you've created and welded into place. Depending on which company you work
for, this is one of the defining features of a vehicle since many of the previous
steps are common between manufacturers. Whether your car has a "ditch
molding" on the roof or simply a smooth continuous roof is an easy way to tell the
difference between cars. The ditch molding is a simpler method where a panel is
placed on top of your vehicle and has an offset surface that allows RSW. The
more complex methods have either brazing or laser welding to produce a
continuous flat surface over the entirety of your roof.

6. Swing metal time. Doors were built up in separate sub-assembly lines and are
placed on a conveyor to be mounted onto the rest of the body. Doors are lifted
via a specially designed piece of tooling to lift them and locate them accurately to
the car body. Bolts are torqued, and verified, to a specific value to mount the
doors. This (along with deck-lids and hoods) are typically the the only threaded
fastener in the entire Body Shop everything else is welded into location.

7. Hoods and deck-lids are placed in a similar manner to doors.

8. At this point the BIW looks like a car without wheels, a chassis, a motor, or an
interior. But it's the right shape. Before moving on there's a final section of the
production line called "body finishing". Imagine a tunnel of fluorescent light
fixtures with cars running down its center and people on both side of the
assembly line at 20' intervals. The purpose is to identify and fix any problems or
defects that would show up once painted. Workers sand and smooth the body
panels to ensure no problems

9. Transfer to paint shop. Depending on the size of the factory this takes a few
forms, usually your BIW gets to ride on some form of conveyor or AGV
(automatic guided vehicle), ride up an elevator or hoist of some sort, and ride
another conveyor before arriving in the paint shop.
There are other additions :

1. Paper work are the first stage ,drawing of the car and finalising
it(BODY DESIGN) .

2. Later the dimensions length breadth of the car , then the required
CHASSIS design .

3. Designing the outer body with some aerodynamic design .

4. Then CAD design is made , showing the structure of the car in a

5. Listing the required parts needed and estimating the value (Stell
requirement and some available accessory parts ) .

6. If found unconvincing budget some part will be removed from the

design , further the sketch moves .

7. Engine is designed as per the body weight of the car ,and what kind of
car it suppose to be ( SUV ,SEDAN ,HATCHBACK ) .

8. Engine design is done if extra space is required to fit the engine ,

discussion is made if satisfactory opinion arise alteration works Carrys
on .

9. Electrical department comes in action , once everything is fine the car

in the paper's goes to factory floor .

10. CHASSIS of the car is made , now day's robots construct the chassis
for eliminating error .

11. Like wise welding is done by robots .

12. Buffing processes are carried out to eliminate any rough particle ,
before going for a paint job .

13. Outside body comes in place and doors are fixed for trial which will be
removed simultaneously for other fittings .

14. Then its goes for primer coating which will help for a smooth finish in
the car's paint job later .

15. Then the painting process once again robots ( high end cars are not
painted robots totally hand made like ROLLS ROYCE ) .

16. A person will go through the finishing of the paint .