BIW Technical Interview Question

Q 1. What is 3-2-1 Principle? (Explanation _1)

Ans: Every object in space will have six degrees of freedom. They are 3 linear and 3 rotational degrees of
freedom along X, Y and Z axis. At the time of manufacturing and inspection, the part must be in stable
condition, hence it becomes necessary to restrict all the degrees of freedom. 3-2-1 Principle describes
ways of constraining the 6 degrees of freedom. When a part is placed on a Primary datum, it requires
minimum of 3 points and it constraints 3 degrees of freedom. As the part comes in contact with
secondary datum, it requires at least 2 points of contact, and 2 degrees of freedom will be constrained.
Contact of the part with tertiary datum requires at least one point to constrain 6th degree of freedom.
For Example –
 Consider a block which is having three translation
movement and three rotations along X, Y and Z
direction as shown below.
 If we provide A-datum to Flat base or X-Y plane it
restrict three degree of freedom that is translation along
Z-direction and rotation along X and Y Direction
 Similarly if we provide B-datum to the face which is
perpendicular to A-datum or Y-Z plane it restrict two
degree of freedom that is rotation along Z-direction and
translation along X-direction.
 To restrict translation along Y-direction we need to provide C-datum in Z direction or we need to insert
one pin along Z-direction.
 In this way we can restrict all six degrees of freedom.

3-2-1 Principle (Explanation_2)

1. Every object in space will have six degrees of freedom. They are 3 linear and 3 rotational degrees of
freedom along X, Y and Z axis.
2. At the time of manufacturing and inspection, the part must be in stable condition, hence it becomes
necessary to restrict all the degrees of freedom.3-2-1 Principle describes ways of constraining the 6
degrees of freedom.
3. When a part is placed on a Primary datum with the help of 3 pins along Z-direction, it requires minimum
of 3 points and it constraints 3 degrees of freedom that restricts translation along Z-direction and
rotation along X and Y Direction
4. As the part comes in contact with secondary datum with the help of 2 pins along Y-direction, it requires
at least 2 points of contact, and 2 degrees of freedom will be constrained, that is rotation along Z-
direction and translation along Y-direction.
5. Contact of the part with tertiary datum with the help of 1 pin along X-direction requires at least one
point to constrain 6th degree of freedom, that is translation along X-direction.
6. In this way we can restrict all six degrees of freedom.

Q 1. 3-2-1 Principle (Explanation _3)

Ans. Define: The 3-2-1 method is a work-holding principle where three pins are located on the 1st
principle plane, i.e., either XY, YZ, ZX. And two pins are located on the 2nd plane perpendicular to the
1st plane, and at last, one pin on the plane is mutually perpendicular to the 1st and 2nd planes. The aim
is to constrain the movement of the workpiece along all three axes.
What is it in brief: A fundamental concern in metalworking is locating the part to be machined,
punched, bent, or stamped relative to the work platform (fixture). For example, a CNC machine tool
starts its process at a specific point relative to the fixture and proceeds from there. Hence, the accuracy
with which a part is machined is quite dependent on the accuracy with which it is positioned in the
fixture.
Accurate locating of not just one part, but each and every part that is loaded into the fixture is crucial.
Any variation in part location on the fixture adds to the dimensional tolerance that must be assigned to
the finished parts.
Additionally, the method of supporting and securing the part in the fixture affects not only dimensional
tolerances, but surface finishes as well. This is true because improper supporting or clamping can
temporarily or permanently deform the part. Hence, techniques for supporting and clamping must be
considered together with the method of locating in order to assure repeatability from part-to-part.
Locating of a part to be machined is a three-step process:
1. Supporting
2. Locating (positioning)
3. Holding (clamping)
The Locating Process: Degrees of Freedom In order to completely specify the position in space of a
three-dimensional
Object (such as the cube that’s shown), we refer to six coordinates:

1. Translational position along the X-axis

2. Translational position along the Y-axis
3. Translational position along the Z-axis
4. Rotational position about the X-axis
5. Rotational position about the Y-axis
6. Rotational position about the Z-axis
These six coordinates are known as the six degrees of freedom of a three-dimensional object. As the
double-headed arrows indicate, the translational and rotational positions can vary in either direction
with respect to each of the three axes. To completely prevent movement, all six degrees of freedom
must be restricted.

The Locating Process: 3-2-1 Method

We have two objectives when mounting a part in a fixture for machining:

1. Accurately position the part at the desired coordinates.
2. Restrict all six degrees of freedom so that the part cannot move.
A widely used method of accomplishing these two objectives uses the 3-2-1 principle, so-called because
it entails three steps that employ three, then two, then one fixed points of known location. Since that
adds up to six fixed points, it’s also known as the six point method.
In the three steps of the 3-2-1 method, three mutually perpendicular planes, called datum planes, are
introduced, one at each step. These three planes define the workpiece position, and together with
opposing clamping forces fully constrain the part. Let’s take a look at the details of the 3-2-1 method.

First Plane: Geometry tells us that three points are required to define a plane. This is the "3" in 3-2-1.
So, three specific points are used to define the first plane. Fewer than three points cannot define a
plane, and in the real world dimensional tolerances mean that four or more points will not be coplanar.
A real-world, less than ideally perfect part placed on four or more reference points will, in fact, rest on
only three of the points due to its less than perfect surface. Different parts may rest on different
combinations of three points, resulting in variation between finished parts. A stool can be used to
illustrate this concept. A two-legged stool would certainly be unstable. A three-legged stool sits rock-
solid. A four-legged stool is often found to rock. In the illustration, a three dimensional part, represented
by a cube, is placed on a datum plane defined by three support points. The part’s six degrees of freedom
have now been reduced to three. It can still move along the X or Y axes, and it can still be rotated about
the Z axis. (The part cannot move along the Z axis because it is held against the plane by clamping force.

Second Plane: A second plane, if it is perpendicular to the first, can be defined by two
points, the "2" in 3-2-1. The part is now constrained to one degree of
freedom: movement along the Y axis. (The part cannot move along the
X or Z axes because it is held against the planes by clamping force.)

Third Plane; A third plane, if it is perpendicular to both of the first two

planes, can be defined by one point, the "1" in 3-2-1. The part is
now entirely constrained. It cannot move along or rotate about
the X, Y, or Z axes. (Remember that the part is held against each
of the three planes by clamping force.)
Locating of a part to be machined is a three-step process:
1. Supporting
2. Locating (positioning)
3. Holding (clamping
Supporting
 The part is supported from "below" with reference to the Z axis. (Introduction of the first reference
plane.)
 Gravity positions the part against the support locator.
 Provide adjustable auxiliary support points as needed to prevent deflection.
 Vertical location with respect to the fixture is now established
 The part is positioned horizontally, in the X-Y plane. (Introduction of the second and third reference
planes.)

Holding

 The part is clamped against fixed locators. Therefore, a known and unvarying position of the part is
maintained with respect to the X, Y, and Z axes.
 One strap clamp or clamp arm will restrict the workpiece in three dimensions due to friction between
the workpiece and clamp. However, friction alone may not be enough to prevent the workpiece from
moving during machining.
 Cutting forces will not move a properly supported and clamped part.

Locating
The part is positioned horizontally, in the X-Y plane. (Introduction of the second and third reference
planes).

Q2. Sheet-Metal Manufacturing Processes

Ans: Apart from punching and blanking, several other useful operations are performed with the help
of mechanical presses:
Some of these are listed below:
(i) Bending, (ii) Deep drawing, (iii) Coining, and (iv) Embossing.
These operations are described briefly.
1. Bending
Bending means deforming a flat sheet along a straight line to form the required angle. Various sections
like angles, channels etc., are formed by bending, which may then be used for fabrication of steel
structures. Three common methods of bending are illustrated in Fig.

2. Deep Drawing
• In deep drawing process, we start with a flat metal plate or sheet and convert it into cup shape by
pressing the sheet in the center with a circular punch fitting into a cup shaped die.
• If the depth of cup is more than half its diameter, the process is termed as deep drawing and with a
lesser depth to diameter ratio, it is called shallow drawing. Parts of various geometries and shape are
made by drawing process. The deep drawing process is illustrated in fig.
 3. Coining and Embossing
• Both coining and embossing operations are done ‘cold’ and mechanical presses with punch and die are
used for these operations.
• In embossing, impressions are made on sheet metal in such a manner that the thickness of the sheet
remains uniform all over even after embossing has been done. It means that if one side of the sheet
is raised to form a design, there is a corresponding depression on the other side of the sheet.
• The result of the coining operation is that the design engraved on the top and bottom dies gets
imprinted on the corresponding faces of the blank in relief (i.e., raised material) without the size of the
blank-circumference changing. Coins used as money in daily usage are manufactured in this manner.
Here forces required are much higher, enough to cause plastic-flow of material.
• Basically it is a pressing operation where not much force is needed.

4 . Notching
A shearing operation that removes a section from the outer edge of the metal strip or part

Stamping Operations
Stamping Process:
• Blanking
• Nesting/ Tailor welding of blanks
• Drawing
• Flanging
• Trimming
• Piercing

Q3. Welding Processes

Ans: Welding: "joining metals through heating them to a molten state and fusing them together. A
localized coalescence of metals, wherein coalescence is obtained by heating to suitable temperature,
with or without the application of pressure and with or without the use of filler material. This filler
material has the melting point same as the base material.”
Types:
1 Resistance Welding (RW)
2Resistance Spot Welding (RSW)
3 Resistance Seam Welding (RSEW)
4 Resistance Projection Welding (RPW)

1. Resistance Welding (RW)

A group of fusion welding processes that use a combination of heat and
pressure to accomplish coalescence.
• Heat generated by electrical resistance to current flow at junction to be
welded
• Principal RW process is resistance spot welding (RSW).
Components in Resistance Spot Welding:
• Parts to be welded (usually sheet metal)
• Two opposing electrodes
• Means of applying pressure to squeeze parts between electrodes
• Power supply from which a controlled current can be applied for a
specified time duration
Advantages:
• No filler metal required.
• High production rates possible.
• Lends itself to mechanization and automation, Lower operator skill level
than for arc welding.
• Good repeatability and reliability.
Disadvantages:
High initial equipment cost.
Limited to lap joints for most RW processes.

2. Resistance Spot Welding (RSW)

Resistance welding process in which fusion of faying surfaces of a lap joint is achieved at one location by
opposing electrodes.
• Used to join sheet metal parts.
• Widely used in mass production of automobiles, metal furniture, appliances, and other sheet metal
products-Typical car body has ~ 10,000 spot welds
3.

Resistance Seam Welding (RSEW)

Uses rotating wheel electrodes to produce a series of
overlapping spot welds along lap joint.
It can produce air-tight joints.
Applications:
Gasoline tanks, Automobile mufflers, various sheet metal
containers.

4. Resistance Projection Welding (RPW)

Uses rotating wheel electrodes to produce a series of
overlapping spot welds along lap joint.
It can produce air-tight joints.
Applications: Gasoline tanks.
A resistance welding process in which coalescence
occurs at one or more small contact points on the parts
Contact points determined by design of parts to be
joined
May consist of projections, embossments, or localized
intersections of parts.
(1) Start of operation, contact between parts is at projections, (2) when current is applied, weld nuggets
similar to spot welding are formed at the projections

Q4. What is BIW?

Ans. Car Cabin structure made of steel panels welded or bonded together to create a load carrying
structure & outer skin surfaces which will envelop the interior parts such as seats , instrument panel,
safety systems and driving controls of a car or a truck. The cabin structure is painted in white which is a
primer coat, CED coating which is why the body shell is called “body in white”.

Q5. What is the Symbol and types of Surface Roughness?

Ans. Surface Roughness Symbol and types:
 Q6. What is painting process In paint shop?
Ans. Paint Process:
• Once all the joinery processes done for complete BIW shell, it is then carried out to Paint shop.
• BIW shell dipped into the paint for the further process.
• Paint drain holes are provided to the panels, to drain unnecessary/ extra paint. It will also help to reduce
the corrosion.
• Following figures shows a typical paint shop.

Q7. What are the Sheet Metal Guidelines?

Ans. Angle of Walls along Draw Direction:
• If the angle of walls along draw direction is small, cracks may arise.The angle of such walls should be as
large as possible. Larger the angle, easier it becomes to form/ draw the part.
Angle of Walls along Draw Depth
≥ 6 Deg No production problems
< 6 Deg The possibility of crack generation is high : Hence change of shape is required.
1) Slope Angle for Trim Operation:
• The best productivity and quality are obtained in trim operation when the plane to be trimmed is
oriented perpendicular to the direction of press.
Slope Angle “A”
< 10 Deg No production problems
10 Deg to 15 Undesirable
Deg due to extra cost incurred (Design and maintenance)
> 15 Deg Either step addition or cam operation is required

2. Position of holes-Pitch:
• The minimum distance requirement between two holes (hole pitch) is constrained as follows:
≥ 25 mm No production problem.
13 ~ 25 mm Undesirable due to extra cost incurred; can be produced,
Though
The use of a standard die-button and retainer is not possible.
4 ~ 13 mm Step addition is required, though undesirable.
˂ 4 mm Not possible to produce, shape change is required.

3. Flange Length (F):

3 mm or more
No problem for production.
Less than 3 mm
Undesirable due to special considerations
in tool.
4. Joggle:
• For the design of a joggling, there should be 3 mm flat land after the joggle
blends and the depth of a joggle must be equalizes with the thicknesses of
another sheets.

Q8. What are the Welding Guidelines?

1) When two overlapping parts are welded, provide a joggle as per below
configuration.
X= 5mm minimum.
P= joggle depth equal to thickness of the Part 1
2) When two welding flanges are ending with same edge, one welding flange should have
1.7mm clearance from the other welding flange edge.
3) Minimum flange width after fillet considered for spot welding is 12mm.
4) In straight zones standard spot welding pitch should be 50mm for 5 mm diameter
of spot.
5) Minimum spot weld and hole spacing:

Q 9. What do you understand by Master-Section?

Ans. Concept design / Design support and feasibility study
 Concept surface description
 Generate master sections and component packaging.
 Technical surface description (A class)
 Deciding part configuration / split lines
 Gap & Flush requirement
 Feasibility study & simulations
 Assembly sequence & develop process diagram & spot plan drawings.
 Preliminary weight analysis and bill of material

Q 10. What is the purpose of Reinforcement?

Ans. The purpose of reinforcement is to provide additional strength for the occupants where it is
needed.

Q 11. Materials used for sheet metal

Ans. 1. Reinforcement- HSLA, AHSS, UHSS
2. Panels- DD513, EDD513
3. Structures- E34

Q 12. What are stamping process & its types?

Ans. Stamping is a manufacturing approach that converts coils or sheets of metal into desired geometry
with the help of pressure and dies of the desired shape.
 Progressive die stamping
 Four-slide stamping
 Deep draw stamping
 Short run stamping
 Different Stamping Operations
 Bending
 Blanking
 Piercing
 Drawing
 Embossing
 Coining
 Lancing
 Curling
 Hemming
 Flanging

Q13. What is spring back Effect? And How to avoid it?

Ans - At the end of the forming process, when the part has been released from the forces of the
forming tool, there is a distortion in the shape and dimension of the formed part. This distortion is
termed spring back.
Avoid Springback Effect – Beads, Darts, Offsets, Material selection.

Q14. What Is Nugget diameter Of Spot Gun? And it’s Types?

Ans- 6mm to 8mm
Types Of Spot Gun
1. C type 2. X type

Q15) Why only 16mm flange used for spot Welding?

 Ans - The width of the weld flange is inadequate to allow proper placement of the weld.

Q16. What is Bill of Materials and its types?

Ans: A bill of materials (BOM) is a centralized source of information used to manufacture a product. It is
a list of the items needed to create a product as well as the instructions on how to assemble that
product. Manufacturers that build products start the assembly process by creating a BOM.
 Types Of Bill Of Materials
1. Manufacturing Bill of Materials (M-BOM) - A manufacturing bill of materials (MBOM) contains all the
parts, labels, packaging, and assemblies required to build and ship a finished product to customers. It is
different than an engineering bill of materials (EBOM) which provides the as-designed BOM.

2. Engineering Bill of Materials (E-BOM) - An engineering bill of materials (EBOM) is a product recipe
structured from the design standpoint, rather than the manufacturing standpoint. It originates in
software used by the engineering department, such as computer-aided design or electronic design
automation.

Q17. What is Tensile Strength and Yield Strength?

Ans. 1. Tensile Strength - Tensile strength can be defined as the maximum stress that a material
can bear before breaking when it is allowed to be stretched or pulled.
2. Yield Strength - When a material is stressed by an amount that is less than the materials yield stress it
will only undergo elastic (reversible) strain, and no permanent deformation of the material will occur.
The level of stress that corresponds to the yield point is referred to as the yield strength of the material.

Q18. How do you select material?

Ans: The following factors are considered during the selection of sheet metal thickness and type of
material.
1. Various external forces acting on the sheet metal part during its complete lifecycle.
2. Weight constraints.
3. Cost constraints.
4. Corrosion resistance requirements.
5. Assembly Process.
6. Availability of material.
Q19. What are the Sheet Metal Features in BIW?
Ans. Joggles, Beads, Diabolo, Embossing, Ribs, Etc.

Q20. What is the need of Joggles / Beads / Diabolo?

Ans. Joggle allows the sheet to overlap another piece of metal.
Beads are widely used to stiffen the sheet metal components subjected to the bending loads.
Diabolo to obtain raised or sunken edges for the desired design pattern on the sheet metal.

Q21. What are the uses of Gussets?

 Ans. Gussets are used to stiffen or to strengthen the bended flange without the need of secondary
process.

Q22. What is density of Steel & aluminium?

Ans. Density of Steel – 7850 Kg/M3
Density of aluminium – 2710 Kg/M3

Q23. Why we use aluminium material to make panels instead of steel in BIW?
Ans. We use aluminium material to make panels instead of steel because-
1. Aluminium are light in weight as compare to steel.
2. Aluminium are cheap in cost as compare to steel.
3. Aluminium having low yield stress due to this we can make complex parts which is not possible is steel.
4. Aluminium is easily recyclable.
5. It is about one-third the weight of steel, which makes it ideal for BIW parts that require certain strength-
to-weight ratios.

Q24. What do you mean by Density?

Ans. Density is the measurement of how tightly a material is packed together.
It is defined as the mass per unit volume.
Density Formula: ρ = m/V,
Where, ρ is the density
m is the mass of the object
V is the volume of the object.

Q25. Mass ratio for steel and aluminium.

Ans: Density of aluminium is 2.7 g/cm3, Density of steel is 7.75 g/cm3.
Hence, Aluminium is around 1/3 the weight ratio of steel.

Q26. What is GD&T and its type?

Ans: Geometric dimensioning and tolerance (GD&T) is a system for defining and communicating
engineering tolerances and relationship. It uses a symbolic language on engineering drawings and
computer generated three dimensional solid model that explicitly describe nominal geometry and its
allowable variation. It tells the manufacturing staff and machines what degree of accuracy and
precision is needed on each controlled feature of the part. GD&T is used to define the nominal
(theoretically perfect) geometry of parts and assemblies, to define the allowable variation in form and
possible size of individual features, and to define the allowable variation between features.

Types:-
 Q27 what is Runout? Where it is used?
Ans:
 Runout is how much one given reference feature or features vary with respect to another datum when
the part is rotated 360° around the datum axis. It is essentially a control of a circular feature, and how
much variation it has with the rotational axis. Runout can be called out on any feature that is rotated
about an axis. It is essentially how much “wobble” occurs in the one part feature when referenced to
another.
 In GD&T, runout tolerance is used to control the location of a circular part feature relative to its axis.

Q 28. Types of Cars?

Ans: SUV, Truck, Sedan, Van, Coupe, Wagon, Convertible, Sports car, Diesel, Crossover, Luxury cars,
Hybrid/electric.

Q 29. What is position tolerance?

Ans: A position tolerance is the total permissible variation in the location of a feature about its exact
true position.
Symbol :

The position tolerance is typically associated with the size tolerance of the feature.

Q 30. Sheet Metal welding defects?

Ans:
• Cracks
• Cavities
• Solid inclusions
• Imperfect shape or unacceptable contour
• Incomplete fusion
• Miscellaneous defects

CATIA Interview Questions for Fresher’s

Q 1. What do you mean by CATIA and the scope of the application?

Ans: CATIA is the abbreviated form of Three Dimensions Interactive Applications, which is useful in
various stages of product development, including conceptualization, design, engineering, and
manufacturing.

Q 2. What is the save extension of the sketcher file in CATIA?

Ans: The save extension of the sketcher file in CATIA is CAD Part.

Q 3. Is it possible to enter into sketcher workbench directly?

Ans: No, it's impossible to enter into sketcher workbench directly. We have to go to any other
workbench and from there we can enter the sketcher workbench.

Q 4. What is the difference between geometric and dimensional constraints?

Ans: Geometric constraint is a connection that forces a limitation between one or more geometric
elements. Dimensional constraint is a constraint, which determines the geometric measurement of the
object.

Q 5. How is arc length measured CATIA?

Ans: We can measure an arc length with the help of the MEASURE ITEM command. Sometimes we need
to modify the option for arc length if the option is not enabled prior to the modification in the MEASURE
ITEM command.

Q 6.What do you mean by true dimension and ISO-Constraints?

Ans: 1.True dimension is the desired measurement after the machining. In other words, this is the value
that should be achieved after the machining.
2. If all the degrees of freedom of geometry have been taken up by a reliable combination of
dimensions and fixed geometry, that geometry is said to be ISO-CONSTRAINED.
3. A geometry that has some degrees of freedom is said to be UNDER CONSTRAINED.

CATIA Interview Questions For Experienced

Q 1 . What are the different types of Sweep in Catia?
Ans. There are 4 types of sweep in Catia are-
1. Explict 2. Line
a. With Reference Surface a. Two Limit
b. With Two Guide Curve b. Limit & Middle
c. With pulling direction c. With Reference Surface
d. With Reference Curve
e. With Tangency Surface
f. With Draft Direction
g. With Two Tangency Surface

3 Circle 4. Conic
a Three Guides a. Two Guide Curves
b. Two Guides & Radius b. Three Guide Curves
c. Centre & Two Angles c. Two Guide Curves
d. Centre & Radius d. Five Guide Curves
e. Two Guides & Tangency Surface
f. One Guide & Tangency Surface
g. Limit Curve & Tangency Surface
Q 2. What is the difference between a stacked dimension and chained dimension mode while using
the auto constraint option?
Ans: In stacked dimension, all the proportions will be measured w.r.t the reference, whereas in chains
dimension the proportions will be measured one w.r.t other.

Q 3. What is the difference between symmetry command and mirror command in CATIA?
Ans: In the symmetry command, the original sketch is removed and the new one is created about the
reference plane, but with the help of the mirror command we can retain both the new one and the
original sketch about the reference plane.

Q 4. Differentiate between the trim and the quick trim?

Ans: In the trim option, we can extend a line along with the trimming of other unnecessary elements. In
quick trim, we can only trim a line or curve and can’t expand or minimize it.

Q 5. What is sketch analysis in CATIA? Can we delete useless elements from the sketch, in the sketch
analysis command? If yes, please describe it.
Ans: 1. Sketch Analysis is a very useful tool to check the sketched profile that we draw.
2. If there is an error occurred when you convert it in the solid we can use this tool to see the total
no. of open and closed geometry in a sketch and can either delete it or make it a closed profile or we
can make it isolate.
Q 6. Where do we use the axis? Difference between axis and construction elements?
Ans: Axis is used in creating Shaft which is the revolving feature. Axis is visible in part design mode and
can be selected, but construction elements are invisible in part design mode and can’t be selected.
A construction element is a 2D geometric element that is not used for creating geometry but is used for
positioning other 2D geometric elements. A construction element is represented by dashed lines in a
sketch.

Q 7. How many axes can be created in a single sketch and how can we change the sketch’s reference
plane?
Ans: We can create only one axis in a sketch, if more than one axes are drawn, then only the latest one
will be axis and others will be converted into reference elements.
We can change the sketch’s reference plane by right click on the sketch, whose reference plane is to be
changed and select the change reference plane and then select new references.

Q 8. What is the function of mirror command in sketch and what should we do to remove the relation
between original and mirrored elements?
Ans: Mirror command in sketch creates a copy of the sketch about a reference plane.
If we want to remove the relation between original and mirror elements we need to explode and the
relation between the original and mirror elements will be removed.