Technological Innovations in Body in White Manufacturing of the ...
Technological Innovations in Body in White Manufacturing of the ...
Technological Innovations in Body in White Manufacturing of the ...
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BMW<br />
Group<br />
<strong>Technological</strong> <strong>Innovations</strong> <strong>in</strong> <strong>Body</strong> <strong>in</strong><br />
<strong>White</strong> Manufactur<strong>in</strong>g <strong>of</strong> <strong>the</strong> BMW X6<br />
Markus Pfestorf<br />
BMW Group<br />
Duane Copeland<br />
BMW MC<br />
w w w . a u t o s t e e l . o r g
BMW<br />
Group<br />
• <strong>Body</strong> <strong>in</strong> <strong>White</strong> Requirements for EfficientDynamics<br />
• <strong>Body</strong> <strong>in</strong> <strong>White</strong> Materials<br />
• Ultra High Strength Steel Grades<br />
• Jo<strong>in</strong><strong>in</strong>g Technologies<br />
• Conclusion<br />
w w w . a u t o s t e e l . o r g<br />
Content
BMW<br />
Group<br />
Power Tra<strong>in</strong><br />
Aerodynamics<br />
<strong>Body</strong><br />
In<br />
<strong>White</strong><br />
EfficientDynamics<br />
<strong>Body</strong> <strong>in</strong> <strong>White</strong> Requirements<br />
Efficient Dynamics<br />
Weight and Axle<br />
Load Distribution<br />
Axle and<br />
K<strong>in</strong>ematics<br />
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BMW<br />
Group<br />
<strong>Body</strong> <strong>in</strong> <strong>White</strong> Requirements<br />
Cost Efficient Light Weight Design<br />
- Torsional Stiffness <strong>of</strong> 29.000Nm/°<br />
- Implementation <strong>of</strong> Ultra High Strength Steel Grades<br />
- Mixed Material Concept (Steel, Alum<strong>in</strong>um, Thermoplastic)<br />
- Cost Efficient Eng<strong>in</strong>eer<strong>in</strong>g us<strong>in</strong>g exist<strong>in</strong>g Panels with a maximum Design<br />
Differentiation<br />
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Specific Panels<br />
Shared Panels
BMW<br />
Group<br />
Deep Drawn Steel<br />
14%<br />
O<strong>the</strong>rs, 4%<br />
6xxx Alum<strong>in</strong>um, 2%<br />
950 MPa, 3%<br />
680 MPa, 5%<br />
180 MPa<br />
15%<br />
550 MPa, 3%<br />
<strong>Body</strong> <strong>in</strong> <strong>White</strong> Materials<br />
Yield Strength<br />
200-220 MPa, 4 %<br />
260 MPa<br />
7%<br />
380-420 MPa, 25%<br />
300 MPa<br />
18%<br />
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BMW<br />
Group<br />
Average m<strong>in</strong>. Yield Strength R p0,2<br />
500<br />
475<br />
MPa<br />
400<br />
350<br />
300<br />
250<br />
200<br />
150<br />
7´Series<br />
5´Series<br />
<strong>Body</strong>-In-<strong>White</strong> Materials<br />
Average M<strong>in</strong>imum Yield Strength<br />
3´Series<br />
Sports Wagon<br />
3´Series<br />
Sedan<br />
7´Series<br />
Previous X5<br />
3´Series<br />
5´Series Coupé<br />
Sports Wagon<br />
3´Series<br />
Convertible<br />
3´Series<br />
Compact<br />
3´Series Sedan<br />
3´Series Sports W.<br />
5´Series<br />
1´Series<br />
6´Series Convertible<br />
6´Series Coupé<br />
5´Series<br />
Sports Wagon<br />
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Z4<br />
?<br />
3´Series Coupé<br />
Z4´Coupé<br />
1994 1996 1998 2000 2002 2004 2006 2008 2010<br />
2008<br />
Start <strong>of</strong> Production<br />
Current X5<br />
X6
BMW<br />
Group<br />
Average Thickness<br />
1,7<br />
mm<br />
1,5<br />
1,4<br />
1,3<br />
1,2<br />
1,1<br />
1,0<br />
7´Series<br />
5´Series<br />
Previous X5<br />
<strong>Body</strong>-In-<strong>White</strong> Materials<br />
Average Thickness<br />
3´Series Convertible<br />
Z4<br />
Without Advanced<br />
6´Series Convertible<br />
Current X5 X6<br />
6´Series Coupé<br />
3´Series Sports Wagon<br />
7´Series<br />
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5´Series Sports Wagon<br />
1´Series<br />
0,9<br />
1992 1994 1996 1998 2000 2002 2004 2006 2008 2010<br />
Start <strong>of</strong> Production<br />
High Strength Steel
BMW<br />
Group<br />
UHSS – Hot Stamped 22MnB5<br />
Side Crash<br />
Thickness (t)<br />
t = 1.2 mm<br />
t = 2.2 mm<br />
t = 1.4 mm<br />
t = 1.2 mm<br />
Weight Sav<strong>in</strong>gs: 2 kg/side<br />
(compared to a hot stamped part<br />
with a constant thickness)<br />
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Mechanical Values:<br />
Yield Strength R p0,2 : > 950 MPa<br />
Tensile Strength R m : > 1300 MPa
BMW<br />
Group<br />
(Complete Longitud<strong>in</strong>al rear member<br />
<strong>in</strong>clud<strong>in</strong>g o<strong>the</strong>r steel grades)<br />
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UHSS – CP800<br />
Rear Crash<br />
Weight Sav<strong>in</strong>gs for <strong>the</strong><br />
Longitud<strong>in</strong>al Rear Member:<br />
4,4 kg<br />
Mechanical Values:<br />
Yield Strength R p0,2 : 680 - 830 MPa<br />
Tensile Strength R m : 800 - 980 MPa<br />
Elongation A 80 : > 10%
BMW<br />
Group<br />
UHSS – CP800<br />
Rear Crash <strong>of</strong> a Prototype<br />
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BMW<br />
Group<br />
Deformation Force<br />
Yield Strength R p0,2<br />
Tensile Strength R m<br />
Elong. after Fracture A 80<br />
Thickness<br />
200<br />
kN<br />
120<br />
80<br />
40<br />
Mech. Properties Mech. Properties<br />
(as delivered) (180°C, 60 m<strong>in</strong>.)<br />
692 MPa 796 MPa<br />
901 MPa 923 MPa<br />
11,4<br />
10,8<br />
0,99<br />
0,99<br />
157,37 kN (with Bake Harden<strong>in</strong>g Response)<br />
155,84 kN (without Bake Harden<strong>in</strong>g Response)<br />
Deformation Time<br />
±88 mm<br />
Tested pr<strong>of</strong>ile<br />
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UHSS – CP800<br />
Rear Crash<br />
± 118 mm<br />
Specimen after Drop Test
BMW<br />
Group<br />
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UHSS – CP800<br />
X6 Part Application<br />
Thickness <strong>of</strong> all Parts: 1,5 mm
BMW<br />
Group<br />
a<br />
UHSS – CP800<br />
Tool Realization Guidel<strong>in</strong>es<br />
Phase 1 Phase 2 c Phase 3<br />
Tool Change Content : a) Optimize <strong>the</strong> release <strong>of</strong> flange form<br />
b) Optimize <strong>the</strong> draw <strong>of</strong> <strong>the</strong> embossments<br />
c) Increase <strong>the</strong> radii if necessary<br />
d) Optimize <strong>the</strong> trim<br />
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b<br />
d<br />
a
BMW<br />
Group<br />
UHSS – CP800<br />
Clamp<strong>in</strong>g <strong>in</strong> <strong>Body</strong> <strong>in</strong> <strong>White</strong><br />
Secure <strong>the</strong> part fasten<strong>in</strong>g assembly process <strong>in</strong> <strong>the</strong> Prototype Phase.<br />
• Test<strong>in</strong>g <strong>the</strong> Series assembly Tools with <strong>the</strong> Prototype Parts and early<br />
Optimization <strong>of</strong> <strong>the</strong> Clamp<strong>in</strong>g Technology.<br />
• Higher Measurement Stability <strong>in</strong> <strong>the</strong> BIW.<br />
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BMW<br />
Group<br />
Spot Weld<br />
Adhesive Bond<strong>in</strong>g<br />
Jo<strong>in</strong><strong>in</strong>g Technologies<br />
Materials and Jo<strong>in</strong><strong>in</strong>g Technologies<br />
Ma<strong>in</strong> Jo<strong>in</strong><strong>in</strong>g Technologies:<br />
• Resistant Spot Weld<strong>in</strong>g (6643 Spot Welds)<br />
• Adhesive Bond<strong>in</strong>g (116999 mm)<br />
O<strong>the</strong>r Jo<strong>in</strong><strong>in</strong>g Technologies:<br />
• Self Pierce Rivet<strong>in</strong>g (82)<br />
• Cl<strong>in</strong>ch<strong>in</strong>g (53)<br />
• Mig Weld<strong>in</strong>g and Braz<strong>in</strong>g (8053 mm)<br />
• Capacitance Discharge Weld<strong>in</strong>g<br />
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BMW<br />
Group<br />
Applied Adhesives<br />
Local Static Transversal Stiffness <strong>of</strong><br />
<strong>the</strong> Upper Control Arm<br />
Jo<strong>in</strong><strong>in</strong>g Technologies<br />
Benefit <strong>of</strong> Structural Adhesives<br />
Local Static Stiffness<br />
Upper Control Arm<br />
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+ 12%<br />
Static Torsional Stiffness + 2%<br />
Dynamic Stiffness<br />
Benefit on Stiffness<br />
+ 0.1Hz<br />
to<br />
+ 0.3Hz<br />
with Adhesive<br />
without Adhesive<br />
Difference <strong>of</strong> Displacements <strong>of</strong> <strong>the</strong><br />
Spr<strong>in</strong>g Support with and without Adhesive<br />
Application
BMW<br />
Group<br />
Jo<strong>in</strong><strong>in</strong>g Technologies<br />
Alum<strong>in</strong>um Casted Front Shock Tower<br />
Supplier <strong>Body</strong> In <strong>White</strong> Pa<strong>in</strong>t Shop<br />
- High Pressure Vaccum<br />
Cast<strong>in</strong>g<br />
- Heat Treated<br />
- Mach<strong>in</strong>ed<br />
- Cataphoretic Pa<strong>in</strong>t<strong>in</strong>g<br />
- Bond<strong>in</strong>g (ca. 5.4 m)<br />
- Self Pierce Rivets (82<br />
times)<br />
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- PVC Sealant
BMW<br />
Group<br />
Ø52 mm<br />
Ø90 mm<br />
Jo<strong>in</strong><strong>in</strong>g Technologies<br />
Capacitance Discharge Welder<br />
Cold Forged part<br />
Material: C15E2C<br />
Advantages:<br />
- More economical Process<br />
- Less Weld Splatter<br />
- High local connection Stiffness<br />
- Smaller amount <strong>of</strong> Heat <strong>in</strong>troduced <strong>in</strong> Parts dur<strong>in</strong>g<br />
<strong>the</strong> weld<strong>in</strong>g Process<br />
- No Process <strong>in</strong>duced Material Structure Change.<br />
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BMW<br />
Group<br />
Force (kN)<br />
1<br />
Distance (mm)<br />
Force vs. Distance Relationships:<br />
1 Outer projection<br />
2 Inner projection<br />
Jo<strong>in</strong><strong>in</strong>g Technologies<br />
Capacitance Discharge Welder<br />
2<br />
1,0 mm<br />
Internal Weld Seam Evaluation:<br />
- Small Fusion Zone<br />
- Small heat <strong>in</strong>duced Zone<br />
- Cont<strong>in</strong>uous Material Connection<br />
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200 µm
BMW<br />
Group<br />
w w w . a u t o s t e e l . o r g<br />
Conclusion<br />
• Mixed Material light weight Concept for <strong>the</strong> <strong>Body</strong> <strong>in</strong> <strong>White</strong><br />
– 8% Ultra High Strength Steel Grade<br />
– 46% Advanced High Strength Steel Grade<br />
• Significant Weight Sav<strong>in</strong>gs by UHSS<br />
– Hot Formed B- Pillar Re<strong>in</strong>forcement with tailor rolled Blank<br />
– CP800 for Longitud<strong>in</strong>al Rear Member<br />
• Capacitance Discharge Weld<strong>in</strong>g for Bush<strong>in</strong>gs<br />
– High local stiffness<br />
– Extreme short Process Time
BMW<br />
Group<br />
Thank You for Your Attention<br />
w w w . a u t o s t e e l . o r g
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