UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

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2.2.2 Assembly laser welding Sheet hydroforming Laser welding was used in ULSAB to improve static and dynamic strength of joints, for areas where access was available on only one side and for good aesthetic appearance at joint areas. Laser welding also has the benefit of a small heat-affected zone, which reduces dimensional distortion and material property changes. Total length of laser welding in ULSAB is 18,286 mm. Laser cabin ULSAB Final Report 21 Slide Adjustment of Relative Stroke Punch DrawRing
22 The laser welding and laser cutting cabin was equipped with a KUKA KR 125 robot to which the laser heads were attached. The maximum load was 125 kg with a working range of 2410 mm. The laser source was a Rofin Sinar CW 025 Nd:YAG Laser. The maximum output of 2500 watts was transferred through a switching device with two outlets via two 15 m glass fiber cables of 0.6 mm diameter to the laser optic. In addition to the laser cutting head, two types of laser welding heads were used: Laser picker and single roller. Welding requires contact between the surfaces that are being joined, and each of these laser heads employs a different method by which they help ensure zero gap prior to welding. Laser picker Assembly laser welding Single roller ULSAB Final Report
Page 2 and 3: UltraLight Steel Auto Body Final Re
Page 4 and 5: Contents Preface v Introduction vii
Page 6: Preface One of the challenges in re
Page 9 and 10: viii Validation Results During the
Page 12 and 13: 1.1 Benchmarking ULSAB Final Report
Page 14 and 15: 1.2 Design philosophy and architect
Page 16 and 17: ULSAB package drawing front view UL
Page 18 and 19: 1.5 Material selection The selectio
Page 20 and 21: Steel sandwich material was chose f
Page 22 and 23: ULSAB parts list Material Material
Page 24 and 25: ULSAB parts list (cont.) Material M
Page 26 and 27: 280 MPa 2.1 Materials 210 MPa ULSAB
Page 28 and 29: Tailored blank usage Tailored blank
Page 30 and 31: 2.2 Processes 2.1.3 Steel sandwich
Page 34 and 35: 3.1 Early involvement 3.2 Tooling 3
Page 36 and 37: Floor complete assembly: the rear r
Page 38 and 39: ULSAB Final Report 3.5.2 Adhesive b
Page 40 and 41: 4.1 Validation 4.2 CAE Analysis 4.
Page 42 and 43: ULSAB Final Report All simulations
Page 44 and 45: ULSAB Final Report The offset barri
Page 46 and 47: ULSAB Final Report Analysis was set
Page 48 and 49: ULSAB Final Report Side impact set
Page 50 and 51: 4.3 Physical testing ULSAB Final Re
Page 52 and 53: Frequency Hz Model Analysis ULSAB S
Page 54 and 55: 5. Economic Analysis Although light
Page 56 and 57: 5.3 Model scope 5.4 ULSAB results U
Page 58 and 59: 5.4.3 Investments 5.5 Sensitivity a
Page 60 and 61: Comparison of ULSAB with Year 2000

UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

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