Yield Improvement in Stamping Parts of BIW (Body in White) and Chassis

Abstract

One of the governing parameter of fuel economy is weight of an automobile itself. Sheet metal parts contributes more than 50% to weight of an automobile. Economic production of these parts leads to overall cost reduction. An attempt has been made to improve yield of manufacturing process particularly forming process under the dissertation work. Body in White( BIW) and chassis parts were focussed for yield improvement. Concept of minimum material approach, grid analysis and inverse approach were implemented and blank sizes have been proposed for various components. An alternative forming process have been proposed which required smaller blank as compared to present blank size. Appropriate changes have been made in the tools to form the components successfully with the proposed blank. Overall yield improvement of 7.69% has been achieved with 4.36 kg reduction in weight.