Automobile Manufacturing

As an engineering professional who worked in an Automobile Industry for more than thirty years of my life, I used to write a lot on technical areas that were of interest to me. Many of my articles were published in trade journals and I was fortunate enough to have a few books in my name. A few months ago, I along with my son Anand decided it would be nice to digitize these writings and move it to this site. The goal is to eventually have all my writings ported over to this site. The good news is that the process has already started. The bad news is it’s going to take us a long time before we can have all my writings ported over.

Today, I would like to draw your attention to my writings on Automobile Manufacturing. Check it out under My Writings.

Here are the highlights with a brief explanation:

History of automobile manufacturing:
Exactly who invented the motor car is to a great extent lost in the mists of history. Many engineers in different countries were working on the same general lines in the middle of the nineteenth century deriving inspiration from the early steam buses and coaches. They all felt the need for a more compact and convenient prime mover to get into a horseless age. ….

Machining of major engine components – 5Cs:
The present trend is to manufacture only 5Cs – Cylinder block, Cylinder head, Crankshaft, Camshaft, and Connecting rod in-house and procure all other components from vendors. Some prefer to reduce these numbers depending on the availability of reliable vendors nearby. In a newer approach, even for these 5Cs, the roughing operations are being farmed out. The in-house facilities of manufacturing concentrate only on highly value-added, critical, high-technology operations that require high capital investment and can not be expected from vendors with limited resources…..

Transmission gears’ manufacturing:
Gear manufacturing has been one of the most complicated of the metal cutting processes. From the beginning of the century, the demand for better productivity of gear manufacturing equipment was posed by “The Machines that changed the World” i.e. AUTOMOBILES…..

Sheet metal stamping:
Ever increasing competition in automotive industry demands productivity improvements and unit cost reduction. The manufacturing engineers and production managers of car body panels are changing their strategy of operation. The days of ‘a simple washer to a very complicated fender, all in plant stamping facility’, are gone. In-house manufacturing facilities preferably produce only limited number of major car panels……

Auto Body welding:
Some 250~300 pressed panels from in-house and vendor facilities are brought to different subassembly stations of Body Weld Shop. Mainly resistance welding and other joining methods carry out subassemblies of pressed components in a planned sequence at number of stations. Some subassemblies are done in off-line manufacturing cells and fed in at appropriate locations into the main assembly line…

Automobile Painting:
All automobile users seek for a chemically resistant, mechanically durable, pleasant in appearance and finish painting. Design constraints of product, customer preferences, and local government regulations related to environmental control – all affect the painting process decisions. A close and effective interaction between the concerned experts from auto-plant, paint process plants, paint application equipment, and paint as well as chemical plant/s are essential for achieving the highest possible paint-shop efficiency…

Assembly and testing of cars:
Assembly of some 2000-3000 interior and exterior parts as well as major components are fitted on painted body in assembly plant that is generally constituted of :Trim Line,Chassis Line, and
Final Assembly Line….

Feel free to read/share the content with your friends in automobile industry.

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