DESIGN AND DEVELOPMENT OF A CHECKING FIXTURE FOR AN

AUTOMOTIVE PRESS PART

This report submitted in accordance with requirement of the University Teknikal Malaysia

Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Engineering Design)

(Hons.)

by

MUHAMMAD HAFIZZUL SAFFUWAN BIN ABDUL JALIL

B051410096

931224-08-6081

FACULTY OF MANUFACTURING ENGINEERING

2017

Disahkan oleh:

_____________________________ ______________________________

Alamat Tetap: Cop Rasmi: 45A, Jalan Besar, Masjid Tinggi, 34300, Bagan Serai, Perak Darul Ridzuan. Tarikh: _______________________ Tarikh: _______________________

*Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

Tajuk: DESIGN AND DEVELOPMENT OF A CHECKING FIXTURE FOR AN AUTOMOTIVE PRESS PART

Sesi Pengajian: 2016/2017 Semester 2 Saya MUHAMMAD HAFIZZUL SAFFUWAN BIN ABDUL JALIL (931224-08-6081) mengaku membenarkan Laporan Projek Sarjana Muda (PSM) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi. 4. *Sila tandakan (√)

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/ badan di mana penyelidikan dijalankan)

SULIT

TERHAD

TIDAK TERHAD

DECLARATION

I hereby, declared this report entitled “Design and Development of a Checking Fixture for an

Automotive Press Part” is the results of my own research except as cited in reference.

Signature : …………………………………..

Author’s Name : MUHAMMAD HAFIZZUL SAFFUWAN BIN ABDUL JALIL

Date : …………………………………..

APPROVAL

This report is submitted to the Faculty of Manufacturing engineering of Universiti Teknikal

Malaysia Melaka as a partial fulfillment of the requirements for the degree of Bachelor of

Manufacturing Engineering (Manufacturing Design) (Hons.). The member of the supervisory

committee is as follow:

…………………………….

(WAHYONO SAPTO WIDODO)

i

ABSTRAK

Projek ini mengenai reka bentuk dan penghasilan sebuah alat memeriksa kualiti untuk

komponen automotif. Objektif bagi projek ini ialah untuk mereka bentuk dan menghasilkan

sebuah alat memeriksa kualiti untuk komponen automotif. Selain itu, ianya juga untuk

memeriksa kualiti komponen automotif atau kepingan besi. Permasalahan dalam projek ini

ialah untuk memeriksa komponen automotif bagi memastikan tahap kualiti sesebuah

komponen automotif mengikut standard piawaian yang telah ditetapkan daripada komponen

yang asal. Bahagian kritikal di dalam produk ini ialah kedudukan ‘datum’ dan had yang

dibenarkan dalam setiap spesifikasi. Maka, setiap bahagian kritikal perlu dinilai dengan

terperinci supaya bahagian kepingan besi berada dalam keadaan yang baik dan melancarkan

operasi pemasangan. Kaedah yang digunakan untuk reka bentuk dan menghasilkan alat

memeriksa kualiti ialah bermula dari peringkat reka bentuk, dimana kaedah kejuruteraan

pembalikan digunakan untuk mendapat data geometri daripada bahagian kepingan besi yang

sebenar. Selepas itu, bahagian edit menggunakan perisian reka bentuk seperti EXScan8,

GeoMagic Studio 10 dan CATIA V5R19 bagi mendapatkan keputusan yang lebih baik dan

menghasilkan lukisan yang lebih terperinci. Proses pembuatan termasuk pemesinan mudah

dan susah, dimana pemesinan mudah mengandungi pembuatan pin ‘locator’ dan ‘bushing’;

dan pemesinan susah termasuk pemasangan semua komponen menjadi satu alat memeriksa

kualiti. Akhir sekali, pemeriksaan kualiti dilakukan menggunakan produk sebenar bersama

alat memeriksa kualiti dan borang semakan kualiti.

ii

ABSTRACT

This project is about the design and development of a checking fixture for an automotive press

part. The objectives of this project are to design and develop the checking fixture for

automotive press part. Besides that, it also to make quality inspection of automotive presses

part or sheet metal part. The problem statement of this project is to make the inspection for

metal press part to ensure that the quality of the automotive press part follow the standard

specification from the original part. Critical parts of the product are datum and tolerance. So,

every critical part needs to evaluate in detail to ensure that the sheet metal part in good

condition and smooth operation during production line. The methods that used for design and

develop the checking fixture are start from the design stage, whereby the reverse engineering

used to obtain the geometrical data from actual metal press part. After that, the editing part

using design software such as EXScan8, GeoMagic Studio 10 and CATIA V5R19 are used to

get the better result and produce the detailed drawing. The manufacturing process involved the

simple and complex machining, which are the simple machining contain the making of simple

locator and bushing pin; and complex machining contain the assembly of all part until

produced the checking fixture. Lastly, the quality inspection has been done using actual

product together with the checking fixture and check sheet form.

iii

DEDICATION

To my late father,

Abdul Jalil bin Jaberal @ Saberan

My beloved mother,

Shahrina binti Sulaiman

My brothers and sister,

Muhammad Syafiq bin Abdul Jalil

Nur A’mirah Syuhada binti Abdul Jalil

Muhammad Danial bin Abdul Jalil

iv

ACKNOWLEDGEMENT

In the name of ALLAH, the most gracious, the most merciful, with the highest praise

to complete this final year project successfully without difficulty.

I am deeply indebted to my respected supervisor, Sir Wayhono Sapto Widodo for his

kind supervision, advice and guide as well as exposing me with meaningful experiences

throughout the project and study. Besides that, his supervision and support that gave me truly

helps during the period of conducting my final year project.

Next, I would like to dedicate my thankful to machinery laboratory technicians, who

has been so warmth and kind to provide sincere assistance and good cooperation during the

final year project period. Furthermore, I would like to thanks to FKP lecturer for their

assistance that spend their time to teach me a lot of knowledge regarding to the design

development.

Finally, I would like to expand my sincere appreciation to my beloved family and my

friends for being very understanding, kind and supportive during completion of this final year

project. My appreciation also goes to all those who help me directly and indirectly in

completing this report. Thank you.

v

TABLE OF CONTENT

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables viii

List of Figures ix

List of Abbreviations xii

CHAPTER 1: INTRODUCTION 1

1.1 Background 1

1.2 Problem Statement 2

1.3 Objectives 3

1.4 Scope of Work 4

CHAPTER 2: LITERATURE REVIEW 5

2.1 Checking Fixture 5

2.1.1 Definition 5

2.1.2 Types of checking fixture 6

vi

2.1.3 Functions, components and fixture design process 8

2.1.4 Checking fixture for automotive press part 11

2.2 Automotive Body Part 12

2.3 Automotive Stamping Process 13

2.4 Reverse Engineering 15

2.5 Computer Aided Design System 18

CHAPTER 3: METHODOLOGY 19

3.1 Project Planning 19

3.2 Relationship between Objective and Methodology 21

3.3 Identifying the Problems 21

3.4 Material Selection 24

3.5 Machining Process 25

3.5.1 Main base 25

3.5.2 Main fixture 26

3.5.3 Others 26

3.6 Check Sheet Form 26

CHAPTER 4: RESULT & DISCUSSION 27

4.1 Geometrical Data in Point Cloud 27

4.1.1 3D Scanner Device 28

4.1.2 Editing Part 30

4.2 Design Modeling 34

4.2.1 3D Drawing for each Part and Functions 34

4.2.2 Assembly Drawing 36

4.2.3 Exploded View 37

4.2.4 Consideration of each Position 38

4.2.4.1 Datum 38

vii

4.2.4.2 Fixture Base and Toggle Clamp 39

4.3 Material Selection 40

4.4 Manufacturing Processes 41

4.4.1 Simple Machining 42

4.4.2 Complex Machining 43

4.5 Check Sheet Form 47

CHAPTER 5: CONCLUSION & RECOMMENDATION 50

5.1 Recommendations 51

5.2 Sustainability of Checking Fixture 52

REFERENCES 53

APPENDICES 57

viii

LIST OF TABLES

2.1 The specifications of the Rexcan CS2+ 17

3.1 The relationship between objective and methodology 21

4.1 The 3D drawing for each part and its functions 35

ix

LIST OF FIGURES

1.1 Example of checking fixture 2

2.1 Example of gauging fixture 7

2.2 Example of measuring fixture 8

2.3 Example of checking fixture for car fender part 8

2.4 The fixture design process 9

2.5 The element of the fixture design process 10

2.6 Various types of checking fixture 11

2.7 Car door panel 13

2.8 Process parameters in the sheet metal stamping of an auto body part 14

2.9 Basic phases of reverse engineering 16

2.10 Rexcan CS2+ 3D Scanner 17

3.1 Flowchart of the project 20

3.2 Step to identify problems 22

3.3 Metal press part 23

3.4 Example of checking fixture made from aluminum or steel 24

x

3.5 Main base with base support 25

4.1 Rexcan CS2+ 3D Scanner with EXScan8 software 28

4.2 The process of capture the point cloud data 29

4.3 The point cloud data before through the editing process 30

4.4 The process of combining each part using EXScan8 software 31

4.5 The process of editing using GeoMagic Studio 10 32

4.6 The mesh creation process 33

4.7 The flip edges process 33

4.8 The finishing product after editing process 34

4.9 Assembly drawing of checking fixture 36

4.10 Exploded view of checking fixture 37

4.11 The location of datum point 38

4.12 The location of main fixture and toggle clamp 39

4.13 Defect area 41

4.14 Locator pin 42

4.15 Bushing pin 42

4.16 The initial main fixture 43

4.17 The toggle clamp with base 44

4.18 The initial assemble of checking fixture 45

4.19 The initial assemble of checking fixture 45

xi

4.20 Finishing product with tolerances side 46

4.21 Final product of checking fixture 47

4.22 Critical point 48

4.23 Example of inspection check sheet 49

xii

LIST OF ABBREVIATIONS

CF - Checking Fixture

3D - 3 Dimension

CAD - Computer Aided Design

CATIA V5 - Computer Aided Three Interactive Application Version 5

CNC - Computer Numerical Control

SOP - Standard Operating Procedure

GDT - Geometrical, Dimensional and Tolerances

1

CHAPTER 1

INTRODUCTION

This chapter will describe the introduction of the project. It includes the background,

problem statement, objectives and the scope of work of this project. The investigation of

checking fixture also involved in this project.

1.1 Background

Jigs and fixtures are tool for process in production line such as machine, assembly and

inspection. These tools are specializing in their scope whereby work holding and tool guiding

device. According to Edward Hoffman (2011), jig and fixture can be described as a device to

hold the workpiece in production and make manufacture part more accurate. The relationship

between cutter, workpiece and other tool must be aligned and maintained. To ensure that

process will run smoothly, a jig and fixture is created to give support, hold, and clamp the

product to make sure each of the manufacture process such as drilled under the specified limits

and tolerances.

2

Checking fixture is one of the important tools that used in industry. Every part that

produced must follow the standard measurement given and to ensure the quality of the

product. According to Edward Hoffman (2011), the main requirement of an inspection fixture

is accuracy. Each inspection fixture should contain only those element needed to check the

specified sizes of forms. Furthermore, a jig and fixture especially checking fixture is the

production tools that to measure the accuracy of manufacture of duplicate product and

interchangeable part. This tool is to ensure that the error and quality issue of the part will solve

and also can smooth the production line in the large of the number. Besides that, it can scale

and measure the complicated design part and productivity of parts into the final assembly line.

Figure 1.1: Example of checking fixture (DongGuan FongYi Precision Tooling Co., Ltd, 2011).

1.2 Problem Statement

Nowadays, the industrial sector rapidly growth due to the economics and market

demand. As the high demand from the customer, every industry needs to increase their

production due to the market needed. One of the machines that can increase the productivity

3

and reduce lead time is stamping machine. Although the productions increase, it must follow

the standard specification from the original part. The most appropriate tool to measure the part

produce is checking fixture.

A checking fixture is required to perform quality inspection process of a sheet metal

part of component. The sheet metal part need to pass the quality inspection by human to

ensure that is smooth operation and do not have any problem during assembly production.

Critical parts of the product are datum and tolerance. Every critical part needs to evaluate in

detail to ensure that the sheet metal part in a good condition and smooth operation during

production line.

1.3 Objectives

The main purpose of this study is to make the design and development of a checking

fixture for an automotive press part.

The objectives of this study are:

(a) To design the checking fixture for automotive press part.

(b) To develop the checking fixture for automotive press part.

(c) To make quality inspection check sheet of automotive press part or sheet metal

part.

4

1.4 Scope of Work

In this study, the main focused on the design and development of a checking fixture for

an automotive press part. The automotive part that will used is the reinforced front panel

within need to use the stamping press machine and one of the main component in automotive

door panel. The reinforced front panel must follow the specific requirement and accurate with

the mold so that it will suit to the body part.

5

CHAPTER 2

LITERATURE REVIEW

This chapter will describe the summarizing of all literature review gathered from the

many academic resources. It includes the study of checking fixture, automotive body part, and

automotive stamping process. Besides that, this chapter also will summarize the method that

will involve in this project.

2.1 Checking Fixture

2.1.1 Definition

Checking fixture (CF) or in other word is inspection fixture, the tools that can we make

a quality inspection of the part or product. For some the reasons, making a checking fixture

need a lot of experience because this tools highly complex process for human designer like

automotive press parts. Furthermore, checking fixture is used to locating and holding the

product part in 3D surface area to ensure the quality, tolerances, etc. The checking fixture are

very useful for monitoring the quality issue of finishing or semi-finishing parts due to the

procedures and standardize the quality in automotive industries also part suppliers.

6

Furthermore, the checking fixture is to verify the geometric feature of product,

dimensions and tolerances according to the design specification. Basically, it can define the

accurate of design dimension, surface geometry and the correct position of the surface.

Specification of the checking fixture to ensure that the accuracy and efficiency of the quality

control procedure and it easy to use, reliability, low cost and simple construction of service.

The importance things about these tools are:

(a) It should have the specific element needed to check the sizes according to design

specification.

(b) It used to make sure the part is produce in standard shape and size requirement.

(c) High accuracy of the standardize product.

According to Prakash Hiralal Joshi (2010), stated that the inspection fixtures is one of

the inspection devices that high precision and interchangeability. Besides that, the uniformity

of the devices must be in limited. Furthermore, the devices also need to be taken into the

capability of the machine. In addition, the several of the variation in size or hole should to be

taken as important data and must be allowed for some of economic reasons. Moreover, the

inspection fixtures are very important in industry because it can speed up the inspection

procedure to increase the rate of the manufacturing in industry.

2.1.2 Types of checking fixture

There are consists of two types checking fixture:

(a) Gauging fixtures.

These fixtures used to inspect a part against of standard size. For examples, it to

check whether the part will pass through the fixtures follows the standard part. If

7

the part too large or small, it will not fit to the fixtures. It also more like to Go-No

gauge. Figure 2.1 below show the example of gauging fixture available at market.

Figure 2.1: Example of gauging fixture (Marposs S.p.A, 2016).

(b) Measuring fixtures.

These fixtures to ensure that how much the part will be detect out of tolerances.

The part will be located on the center of the fixtures and the locator will used to

ensure that the datum and tolerances at higher inspect. It consists of the gauging

fixtures, locating, clamping and mounted elements in the body of the fixtures.

Furthermore, the used of check sheet will more helpful during quality inspection.

Figure 2.2 below shot the example of measuring fixture for body part of car.

8

Figure 2.2: Example of measuring fixture (Witte Barskamp KG, 2016).

2.1.3 Functions, components and fixture design process

Typically, the checking fixture consists of three functions whereby the locating of part,

clamping area and checking the critical part or datum. Figure 2.3 below is example of

checking fixture for car fender part and all the function will place on the workbench.

Figure 2.3: Example of checking fixture for car fender part (Hu Cai-qi et al., 2005).