Interview typical 100 questions for BIW Fixture Design Engineer position

Dear Friends,

Most of the engineers working in BIW fixture domain change their job due to various reason career growth, market situation ,
etc.

If you are a fresher or experienced engineers then you will curious what questions will be asked.

How I should prepare for the interview?

If you ask me actually there is no guess which questions will be asked as it depends upon the job requirement , company
work area whether they are OEM,Tier 1 , Line builder or Engineering service company and also the exp. of the interviewer and
most important what you have written in your curriculum vitae

I will try to give fews questions., not necessarily they come in sequence or in terms of only Yes or No type.

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Few questions on BIW if the interviewer is looking someone to do BIW fixture design and detailing work .

1) What is BIW?

Ans: Body in White ( Sheet Metal Body structure joined via spot, MIG/TIG or laser welding )

Detailed explained earlier blog

2) What is 3-2-1- principle ? Please explain.

Ans - Detailed answer given in earlier blog.

3) What is PLP or RPS ? Please explain

Ans- Principle Location Point

4) Why shimming is done BIW fixture?

Ans - Detailed answer given in blog.

General answer to take care sheet metal manufacturing tolerance ( mostly profile , and position tolerance)

5) Why 2 way shimming is done in panel?

Ans: For hole to adjust in both direction and for panel if the panel and mylar intersection angle is more than 15%

6) What is Mylar? or What is Rest block or Clamp block ?Explain

Ans: Rest or Clamp block which is holding panel.

7) What is Riser? Is it gascut or welded structure?

Ans: Welded or gas cut structure which is mounted on base plate and hold rest,clamp block and clamp or location pin.
8) Why dowels are used in BIW?

Ans: Dowel is hardened turned component mostly having press fit tolerance used to location two different parts or assemblies
together.

9) What is tolerance on dowel?

Ans : Mostly M6

10) What is general thickness of Mylar?

Ans : Depends upon steel or Plastic mylar; generally for steel 20x20 ( cross section) and 50x50 for plastic ( S Grun/ Teflon)

11) Do you need to do hardening for Mylar? Which hardening process?

Ans : To avoid wear of mylar . If not hardened size will get reduced over the period due to continuous use and which will
result in accuracy or assy. welded

12) What is 4 way or 2 way location?

13) What is difference between round pin or diamond pin?

14) What will be tolerance on location pin?

15) What will be tolerance on locaton pin?

16) What are the thickness of shims used below mylars?

17) Why Rough locators are used in BIW fixture?

18) What is purpose of rough locator?

19) What should be location pin size if I have A class panel hole of dia 10 and hole tol. is 0.1?

20) Which screws are are better allen screw or hexagon head?

21) How much should be depth of thread if I use M8 tapping to mount myar on riser?

22) What is J riser? What is mfg .process ? What is its thickness?

23) What will be min . height for location pin straight portion for the panel location?

24) What will be hardness for location pin? What will be hardening process?

25) What is clamping scheme?

26) What is Spot Welding process?

27) What is MIG?

28) What is nugget diameter?

29) What should be distance between two spots?

30) What should be min. flange width for welding of 2 panels?

31) How many panels can be spot welded together 2,3 or 4 panels at a time?

32) What should be thickness ratio for welding 2 or 3 panels?

33) Can we weld 0.5 mm thick with 2mm?

34) What is cycle time?

35) What is takt time?

36) How much time it takes to weld one spot?

37) What is weld sequence?

38) How much current needed to do spot weld?

39) What is C or X or Y gun?

40) What is IT or Non IT Gun?

41) What is diameter of welding electrode?

42) How weld strength is checked? What are the different tests?

44) What is general diameter of electrode?

45) What is the material of the electrode?

46) After how many spots electrode has to be changed?

47) What is tip dressing?

48) How many times I can use main PLP location hole ?

49) Why I need flanged hole?

50) What is panel inspection fixture? Why it is necessary?

51) Do you have any idea about welding inspection fixture?

52) What is working height of manual welding fixture?

55) What is proximity sensor? Why it is used?

56) What is NAAMS Standard?

57) What will be tolerance on mylar block if it fitted on Riser? Clear, tight or interference fit

58) Why water is used in spot welding gun?

59) Can we do aluminium panel welding?

60) What is roller hemming? Where it is used?

61) How hemming is done?

62) What should be height of panel for roller hemming?

63) How many steps followed for roller hemming?

64) How much height we should have at the corner of the door?
65) Why sealant used in BIW?

66) What is difference between coated sheet and non coated sheet?

67) Which panel needed max current coated or non coated?

68) What is puddle welding?

69) What is MIG welding? Is it used in car BIW?

70) How Mylars are checked?

71) What is the purpose of CMM machine in BIW?

72) What is FARO?

73) What is accuracy of FARO Arm?

74) What is general speed of roller hemming robot ( in terms of mm/min)

75) What is toggle clamp?

76) Why toggle clamp used in BIW welding fixture?

77) Why toggle clamp pivot point and PLP should be in one line?

78) What is gripper?

77) Why grippers are used?

79) Can I mount weld gun and gripper on the same robot?

80) What are light curtains?

81) What is gantry?

82) What is lift and carry mechanism?

83) What is shuttle system?

84) What is framing station?

85) What is Geo Station?

86) What is respot station?

87) What is chisel test?

88) What is S-Grun material?

89) What is teflon material?

90) Why stress relieving has to be done after welding?

91) Why dowel holes are made on base plates?

92) What is blackodising ? Why it is done?

93) Do you apply pressure on panel during toggle clamping?

94) Why BIW tools are designed for Left Hand side only? For Chassis component

95) What are carlines?

96) Where is car origin? X=0,Y=0,Z=0

97) Why one round hole and one slot strategy followed for deciding PLP of panel?

98) Is it possible for to use Hole -Hole strategy? Who is using it now?

99) Can we weld aluminium with steel?

100) What is water jet cutting? Is it used in BIW fixturing?

101) What is gas cutting? Can I cut St 52-3 mat. 200thk by gas cutting?

102) Have you used laser cutting for 10mm thk plate?