Journal of Advanced Research in Mechanical Engineering and Technology

Volume 10, Print Issue 2 - 2023, Pg. No. 1-17

Peer Reviewed Journal
Research Article

Design and Development of BIW Fixture for Front

Windshield With Manual Loading, Unloading &
Welding
SG. Bhardiya1, Kumar S. Khandekar2, Prathmesh S. Mule3, Ashish Koli4, Akshay Madne5
1
Assistant Professor, Research Scholar, Department of Mechanical Engineering, Sharad Institute of Technology College of
Engineering, Yadrav, Ichalkarnji, Maharashtra, India.
2,3,4,5
Research Scholar, Department of Mechanical Engineering, Sharad Institute of Technology College of Engineering, Yadrav,
Ichalkarnji, Maharashtra, India.

I N F O A B S T R A C T

Corresponding Author: Today’s welding fixtures for the automotive industry are crucial for
Assistant Professar, Scholar, Department of auxiliary welding. The body of the car is welded together using numerous
Mechanical Engineering, Sharad Institute of intricate sheet sections and additional support pieces. The welding
Technology College of Engineering, Yadrav, fixture’s supporting role is an essential element in this project’s process.
Ichalkarnji, Maharashtra, India.
The phrase “Body in White” (BIW) is frequently used in the automotive
E-mail Id:
industry to refer to the sheet metal-welded construction of the car.
[email protected]
Automobile BIW is currently constructed of steel and an aluminum
How to cite this article:
alloy. The BIW component is joined using a variety of metal joining
Bhardiya SG, Khandekar KS, Mule PS et al. Design
techniques, such as MIG welding, to create a welded metal shell known
and Development of BIW Fixture for Front
as Body in White.
Windshield With Manual Loading, Unloading
& Welding. J Adv Res Mech Engi Tech 2023; We need to construct a BIW fixture in order to weld it together. Fixtures
10(2): 1-17. are used to firmly anchor in a particular spot or to assist work, assuring
the interchangeability and conformance of all parts produced using the
Date of Submission: 2023-07-15
fixture. The placement of the spot welds is to be determined in the
Date of Acceptance: 2023-08-12
welding fixture design. The clamps, locators, rest mylar, riser, clamp
cylinder are included in the location and orientation of the fixture. At
the setup planning stage, fixture design is crucial. The fixture setup
is done manually in the current design due to the surface finish and
precision of the machined pieces. Software called Catia is used to
design the fixture.
Keywords: Fixture, Windshield, Design, Mylar, Drafting, Assembly,
Model

Introduction necessary, auxiliary devices. A welding fixture is also included

to retain the automobile panels in the appropriate position
Car Body-In-White (BIW) is a complex steel structure
despite thermal distortions.2 Automobile manufacturers
comprising 300–500 sheets of steel with intricate shapes
are under ongoing market pressure to provide customers
that are assembled using welding in rapid succession at 55–
with more product and variant options in shorter lead
75 robotic workstations.1 A robotic welding station typically
times while also seeking reduced production costs.3 A
consists of the following components: a robot with a welding
single station or cell must be able to handle various models
gun; a control system for the robot; welding equipmen, if
Journal of Advanced Research in Mechanical Engineering and Technology (ISSN: 2454-8650)
Copyright (c) 2023: Author(s). Published by: Advanced Research Publications
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without necessitating a complete redesign of its apparatus Stage 1 assembly & Stage 1 assembly & Welding
to satisfy these obviously incompatible objectives.4 Body
Marked highlighted area consider first loading
in White refers to an automobile’s unpainted body shell.
Any car’s external and interior design are determined by
BIW joinery.7 With the aid of various brackets or nuts put
on the BIW, all interior parts (often used in automobiles)
such as the dashboard, trim (door trim, pillar trims, roof
liner, seats are mounted on the BIW shell.5 With the use
of various brackets or mounting systems, exterior (a term
commonly used in the automotive industry) components6
such as the front bumper, rear bumper, fender LH/RH, side
mirrors are attached on the BIW shell.
Elements In Fixture
The toolbody serves as the mounting framework for the entire
fixture. It can shape the primary bulk of the fixture and be
produced from a variety of materials using various processes.
Elements for enduring the force include supports. The bulk
of the component, machining forces (if any), clamping forces
are some of these forces. Supports are properly positioning
their contact points and supporting the part against these
Figure 3.Assembly & Welding
forces. Locators are utilised to maintain the part in its proper
location.Together with supports, they establish a special Stage 2 Assembly & Welding
technique for maintaining the part’s proper orientation and Marked highlighted area Consider Loading Panel
position. As implied by the name, clamps are objects that
grab hold of fixture components. They are making sure the
part will be held in the fixture firmly and tightly throughout
the procedure. Optional components include Lifting Devices,
Ejectors, Spring-Stop Buttons, Spring Locating Pins. Their use
depends on the fixture’s size, price, intended use.are used
to actuate the Rover, which is supported by a bridge circuit
and may travel in any direction.
Input Parameter and Customer Requirement
• Loading and Unloading of panel should be easily
• Fixture height should be not be more of 3 ft
• Fixture will be done by considering full-proof concept
• Fixture should be such that in doesn’t fall in path of
welding Gun
• All rest and Clamp Mylar must be follow all PLP points
• Open clamp arm which is opposite to operator side
Figure 3.Assembly & Welding
Component Assembly
Procedure to Design BIW Welding Fixture
The following sequence points consider design of BIW
fixture.
Input From Customer
• Fixture require to make manual
• Welding spot and arc also manual
• Use manual toggle clamp
• Mylar should be 3 Hole or 4 Holes
• Use part size 20mm x20mm
• Riser height up to 250mm then thickness riser take
Figure 1.Front Wind Shield
25mm and above take 30mm

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Figure 4.Panel Data

4
5

6
.
8
1 2
Figure 5.Sequence of panel loading

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The Sequence of Panel Loading Mig Welding

While designing BIW fixture require considering the MIG welders use a tool called a spool gun, which feeds a
sequence of panel loading. spooled wire electrode at a selected speed. The gun also
Following sequence-wise panel loading considered. emits a shielding gas as it lays the weld. This gas protects
the weld area from atmospheric gases such as nitrogen
2D Guideline For Design Gun Study: and oxygen, which can cause problems if they come in
This is an important study in fixture design. This gives the contact with the electrode, the arc, or the welding metal.
details of where the weld gun is located, what kind of weld According to given welding data we require to add gun
gun (resistance spot welding, seam welding) is Used. The in 3d model which x type gun & C type gun and some arc
entire fixture design depends on it. welding also. Gun access should be important for welding
after this we can build units to clear gun.
Types of weld & Gun used In BIW Fixture
Following Gun given By Customer:
Spot welding
Many basic types of guns are available, the two most
commonly used for Spot welding, being the direct-acting
type, generally known as a “C”-Type gun, where the
operating cylinder is connected directly to the moving
electrode, the “X” Type (also known as “Scissors” or “Pinch”)
where the operating cylinder is remote from the moving
electrode, the force being applied to it by means of a
lever arm. C guns are generally the cheapest and the most
Fig 8 .X-Type Gun
commonly used. There are many variations available in each
basic type with regard to the shape and style of the frame HalfOpen Condition Full Open Condition

and arms, also the duty for which the gun is designed with Figure 8.X-Type Gun
reference to welding pressure and current.
The above 3d model which is actual gun, used when welding.
The gun have this actual dimension with position of gun
arm while welding and open with full and half condition.
This is mandatory gun data require about gun so easy to
build a unit to clear gun.

Figure 6.X Type Gun

Figure 7.C Type Gun Figure 9.C Type Gun

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This type of gun is usually used when a horizontal gun is Following Standard Parts Given from Customer
not possible which is falling to panels & units.
Shim
Final Gun Study Data
Shims are the small part that comes with a thickness of
Below image shows panel with gun study data. 0.1mm, 0.2mm, 0.5mm, etc. These will compensate the
For Stage 1 Panel welding stack-up tolerance which reflects at the panel holding part
called Mylars. We give tolerance to all the parts of the
fixture. Due to this tolerance the Mylar’s will either lift up
or goes down from its defined position. If the Mylar’s goes
down from the defined height it will make impression or
dent on the panel. If the Mylar’s lift up then there will be
a distortion due to welding stress. To adjust the Mylar’s
At its defined position we use shims so the panel won’t
deformed & also don’t get any impression on it. Shim are
required to use 3 or 4 Slotted depends on hole on Mylar

Figure 11.4 slotted Shim

Figure 10.Gun Data in 3D Figure 12.Pack of shim

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Teel Smith Clamp Height 243.00 mm

Toggle clamps hold the car part firmly and prevent the Weight 1.180 Kg
part from distortion while carrying out the spot welding
operation.
a) HV-700-H& HV-700-V

Figure 14.HV-1200-H& HV-1200-V

Figure 13.HV-700-H & HV-700-V
Table 2.HV-1200-H& HV-1200-V
Table 1.HV-700-H & HV-700-V Model No. HV-1200-H-TM-TU
Model No. HV-700-H H.V. Series Toggle Clamps
Type
H.V. Series Toggle Clamps Straight Base
Type
Straight Base Material Steel
Material Steel Finish Black ED* Coating
Finish Black ED* Coating Arm Type Solid Horizontal Arm
Arm Type Solid Horizontal Arm Base Type Straight Base
Base Type Straight Base Handle Opening (± 3°) 82°
Handle Opening (± 3°) 82 Clamp Bar Opening (± 3°) 110
Clamp Bar Opening (+3°) 100 Holding Capacity 11.80 KN
Holding Capacity 6.90 KN Length 149.00 mm
Length 126.00 mm Width 24.00 mm
Width 20.00 mm Height 298.00 mm
Weight 1.800 Kg

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Pin Slider Block Slider

It is subassembly Unit which used for pin sliding mechanism. It is a subassembly Unit used for Mylar or rests sliding
After completing welding operation pin required to retract mechanism. After completing the welding operation pin is
then this mechanism used. Customer make some standard required to retract then this mechanism is used. Customers
sub assembly which used to make unit. make some standard subassembly which is used to make units.

Pin Holder

Locking Block

Handle

Figure 15.Pin Slider

Locking Handle

Slider

Figure 16.Block Slider

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Concept Design leader we decide no clamp which holds the panel while
welding. For panel No.2 we make a pin unit and a rest and
As per panel sequence loading data, gun data & customer
stopper unit which fix anti-rotation of that panel. All this
standard part we going to design clamp unit, Pin unit & rest
units we build to clear with Gun access.
unit to restrict 12 DOF of each panel. As discuss with team

2
Figure 17.Design for 1st stage Right side Panel

Pin Unit Pin Unit

Figure 18.Panel No. 1 Figure 19.Panel No. 2

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Guideline for Design for Ballon For Pin

Make Part -1to10 Material-20MnCr5 (Round part)
STD Part- (Shim, Riser, Cylinder, Sensor)-141 to160 Heat treatment-50-55 HRC Surface Treatment-Chrome
Hardware-161 to 180 plating

Figure 20.For Ballon

Figure 21.Pin

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For Mylar For Make Part

Material-C45 Material-MS
Heat treatment-50-55 HRC Surface Treatment-Chrome Surface Treatment- Blackodise Available Plate Thickness in
plating (mm):- 8,10,12,15,20,22,25,30,35,40

Figure 22.Mylar

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Figure 23.For Make Part

Material Selection which is important in a fixture that will be used repeatedly.
Additionally, C45 is relatively easy to machine, which can
Mylar & Clamp Mylar
save time and money during the manufacturing process.
C45 is a high-carbon alloy steel that is commonly used
Here is a comparison of C45 to other materials that are
in the automotive industry for its strength, toughness,
commonly used for BIW fixtures:
machinability. It is also relatively inexpensive, making it a
costeffective option for BIW fixtures. As you can see, C45 is a good all-around material for
BIW fixtures. It is strong, tough, machinable, relatively
C45 is a good choice for BIW fixtures because it can
inexpensive. If you are looking for a cost-effective option
withstand the high forces that are applied during the
that can withstand the rigors of the manufacturing process,
manufacturing process. It is also resistant to wear and tear,
C45 is a good choice. Model No.
Table 3
S. No. Material Strength Toughness Machinability Cost
1 C45 Good Good Good Inexpensive
2 AISI 4140 Excellent Excellent Good Expensive
3 Stainless steel Good Excellent Poor Expensive

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Make Part, Clamp Arm, L-Block Riser Here is a comparison of 20MnCr5 to other materials used
for PIN BIW fixtures:
Here are some of the advantages of using MS material for
making parts of BIW fixtures: As you can see, 20MnCr5 has the highest tensile strength
and toughness of the materials listed. It also has good
1. Strength: MS material is very strong and can withstand
machinability and corrosion resistance. This makes it the
a lot of force. This makes it ideal for use in fixtures that
best material for PIN BIW fixtures.
need to support heavy loads.
2. Durability: MS material is also very durable and can Rest Mylar
withstand a lot of wear and tear. This makes it a good Here are some of the advantages of using Teflon material
choice for fixtures that will be used in harsh environments. for the rest mylar of BIW fixtures:
3. Cost-effectiveness: MS material is relatively inexpensive,
making it a cost-effective option for many applications. 1. Low friction: Teflon has a very low coefficient of friction,
4. Ease of fabrication: MS material is easy to fabricate, which means that it resists movement and wear. This
which can save time and money on production. is important in BIW fixtures, as it helps to prevent
5. Environmentally friendly: MS material is recyclable, the workpiece from moving during the manufacturing
which makes it a more environmentally friendly option process.
than some other materials. 2. Chemical Resistance: Teflon is resistant to a wide range
of chemicals, including acids, bases, solvents. This makes
Here are some of the other materials that are commonly it a good choice for fixtures that will be used in harsh
used for making parts of BIW fixtures: environments.
1. Steel: Steel is a strong and durable material, but it can 3. Heat Resistance: Teflon can withstand high temperatures
be more expensive than MS material. without melting or deforming. This makes it a good
2. Aluminum: Aluminum is a lightweight and corrosion- choice for fixtures that will be used in hightemperature
resistant material, but it is not as strong as steel or MS applications.
material. 4. Durability: Teflon is a very durable material that can
3. Plastic: Plastic is a low-cost material that is easy to withstand a lot of wear and tear. This makes it a good
fabricate, but it is not as strong or durable as steel, choice for fixtures that will be used in high-volume
aluminum, or MS material. Overall, MS material is a production environments.
good choice for making parts of BIW fixtures because 5. Non-Stick: Teflon is a non-stick material, which means
it is strong, durable, cost-effective, easy to fabricate, that it does not stick to food or other materials. This
environmentally friendly. is important in BIW fixtures, as it helps to prevent the
workpiece from sticking to the fixture.
Here are some of the reasons why 20MnCr5 is the best
material for PIN BIW fixtures: Here are some of the other materials that are commonly
used for the rest mylar of BIW fixtures:
1. High strength: 20MnCr5 has a high tensile strength of
1000 MPa, which makes it ideal for applications where 1. Nylon: Nylon is a strong, lightweight material that is
high loads are applied. resistant to chemicals and solvents. However, nylon is
2. Good toughness: 20MnCr5 has good toughness, which not as resistant to heat as Teflon.
means that it can resist impact and deformation. This is 2. Aluminum: Aluminum is a strong, lightweight material
important for applications where there is a risk of the that is easy to machine and fabricate. However, aluminum
fixture being dropped or hit. is not as resistant to chemicals and solvents as Teflon.
3. Good Machinability: 20MnCr5 is easy to machine, 3. Polycarbonate: Polycarbonate is a strong, lightweight
which makes it cost-effective to produce fixtures from material that is resistant to impact and chemicals. However,
this material. polycarbonate is not as resistant to heat as Teflon.
4. Corrosion Resistance: 20MnCr5 has good corrosion Overall, Teflon is a good choice for the rest Mylar of BIW
resistance, which is important for applications where fixtures because it is low friction, chemical resistant, heat
the fixture will be exposed to harsh environments. resistant, durable, non-stick, easy to clean.
Table 4
Material Tensile Strength (MPa) Toughness (J/cm2) Machinability Corrosion Resistance
20 MnCr5 1000 270 Good Good
SAE 1045 860 220 Good Fair
AISI 4140 1000 240 Good Good

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Component Fixture Drawing: Mylar Clamp Mylar

Mylar is a type of polyester film that is used in a variety of Clamp Mylar is a type of Mylar that is specifically designed
applications, including BIW fixtures. Mylar is strong and for use in BIW fixtures.
lightweight, it is also resistant to chemicals and heat. This Clamp Mylar is thicker and stronger than regular Mylar, it
makes it a good choice for use in fixtures that will be used is also coated with a special adhesive that helps to prevent
to hold and support car body panels. the panel from slipping.

Figure 24.Mylar

Figure 25.Clamp Mylar

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Rest Mylar Clamp Arm

Rest Mylar is a type of Mylar that is used to support car The clamp arm is the part of the fixture that holds the
body panels in biw fixtures. Rest Mylar is typically thinner panel in place. The clamp arm is typically made of steel
than clamp Mylar, and it is not coated with an adhesive. or aluminum, and it is attached to the fixture base with a
This allows the panel to move freely, which is important for pneumatic cylinder. The pneumatic cylinder allows the clamp
preventing damage to the panel during the manufacturing arm to be opened and closed, which allows the panel to be
process. inserted and removed from the fixture.

Figure 26.Rest Mylar

Figure 27.Clamp Arm

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L-Block Riser
The L-block is a type of block that is used to support The riser is the part of the fixture that raises the clamp
the clamp arm. The L-block is typically made of steel or arm above the base. The riser is typically made of steel
aluminum, and it is attached to the fixture base with bolts. or aluminum, and it is attached to the clamp arm with
The L-block helps to distribute the force of the clamp arm bolts. The riser allows the clamp arm to be positioned at
evenly, which prevents the fixture from becoming damaged. the correct height for the panel that is being worked on.

Figure 28.L-block

Figure 29.Riser

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Drafting of Main Assembly

Figure 30.Drafting Of Main Assembly

3D Model of Fixture

Figure 31.3D Model of Fixture

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List of Fixture Components

Table 5.List Of Fixture Components
Item No. Part No. Product Description QTY Material Weight
1. W-11S-20-001 MYLAR 1 C45 0.372kg
2. W-11S-20-002 CLAMP MYLAR 1 C45 0.326kg
3. W-11S-20-003 REST MYLAR 1 TEFLON 0.352kg
4. W-11S-20-004 CLAMP ARM 1 MS 0.698kg
5. W-11S-20-005 L BLOCK 1 MS 0.455kg
6. W-11S-20-006 RISER 1 MS 3.209kg
7. DE-21-003 SLOTTED SHIM- 5 SLOTS-5THK 5 STD 0.11kg
8. HV-1200- HTM-TU Heavy Duty Horizontal TOGGLE
CLAMP HV1200- HTMTU 1 STD -

Conclusion body-in-black wins design accolade”. Plastics Today.

UBM Indians. Retrieved 1 July 2018.
In this project, a BIW fixture for front windshield with
5. Henriksen, Erik K. (1973). Jig and Fixture Design Manual.
manual loading unloading and welding was designed and
New York
developed. The fixture was designed to meet the following
6. Colvin, Fred H.; Haas, Lucian L. (1938). Jigs and Fixtures:
requirements:
A Reference Book. New York and London: McGraw-Hill
• It should be simple for manual labour to operate and Book Company
strong enough to withstand the stresses created during 7. Production process at Porsche”. Porsche News. F.
welding. Porsche AG. 5 April 2016. Retrieved 13 April 2018.
• Steel was used to manufacture the fixture, which
was created using SolidWorks. The fixture passed all
of the tests and was judged to be in compliance. The
windscreens of several different automobiles were
successfully welded using the device.
• From this project, the following conclusions can be
made: o The effectiveness and calibre of the welding
process can both be greatly enhanced by the use of
a fixture.
• A fixture may be made so that manual labourers may
utilise it with ease.
• It is possible to create fixtures that can withstand the
forces produced during welding. A fixture is a useful
instrument for enhancing the effectiveness and calibre
of the welding.
References
1. Narendra Kumar “BODY IN WHITE FIXTURE
DESIGN”ISSN: 2349-2163 Issue 04, Volume 6 (April
2019).
2. Sadasivam Narayanan & PrabhaShanka “Design of
flexible spot welding cell for Body-In-White (BIW)
assembly’’Vol.6, No.2, October 2018, pp. 24~38.
3. Ali Keyvani “Modular Fixture Design for BIW Lines
Using Process Simulate” University West, Department
of Technology, Mathematics and Computer Science,
S-461 86 Trollhättan, SWEDEN.
4. Plastics Today Staff (8 March 2012). “Carbon fiber

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