University of Twente Student Theses


Increasing tolerances of the body panel fit on a hybrid chassis

Kleissen, R. (2018) Increasing tolerances of the body panel fit on a hybrid chassis.

[img] PDF
Abstract:During the assembly phase of the production at Donkervoort Automobielen, deviations are visible. These deviations mainly in the panel gaps, are also visible at the finalized cars. The fitting of the panels has a large influence on this problem. As after the panels have been joined, they cannot be repositioned. Therefore, possible faults made there are hard to fix from that moment on. The fact that the panels have deviations in their fit, can have two main causes. The chassis or the panel dimensions could be different after production, compared to the designed dimensions. Another cause could be the positioning of panel to chassis that could be out of the designed tolerances. Focus has been laid on the chassis deviations. Mainly this is done as most of the car is depended on the chassis. An optimization of the chassis would also increase positioning of more parts. Out of a comparison with concurrents, a path has been chosen for designing a jig. The purpose of this jig is to detect where the chassis is out of its tolerance field. During the concept phase, the choice is made for a modular jig and focus was laid on measuring suspension, glue surfaces and some of the COP measurement points. During the analyses phase of the jig, also test were done to improve the panel fit. Aluminum shims are used for positioning the panel to the chassis. Due to the limited varieties in thickness, improvement was searched for in a better positioning ’shim’. The solution was found in use of glue as a shim. The tests showed using epoxy glue with aluminum tape on the chassis side of the gap between panel and chassis, was successful in positioning usability. In a simple calculation in the tolerances the importance of a precise fit of the panels became clear. Maximum tolerances were set on the chassis by the dimensions of the measuring jig. To reach the tolerances needed for measuring, a choice on material and production method was of importance to reach the high tolerances. After the design process a measuring jig CAD-model was made. Suspension, glue surfaces and COP points could be measured. The multidisciplinary work of this internship is showed in the token side-track. Experiments were done to get a feel on their own developed EX-CORE. Not only by experimenting with EX-CORE itself but also by building a heated mold, for future production purposes.
Item Type:Internship Report (Master)
Faculty:ET: Engineering Technology
Subject:52 mechanical engineering
Programme:Mechanical Engineering MSc (60439)
Keywords:Donkervoort, Chassis, Jig, Carbon fiber, design, Glue, Mold, Cars
Link to this item:
Export this item as:BibTeX
HTML Citation
Reference Manager


Repository Staff Only: item control page