Post on 16-Oct-2015
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Technological Innovations in Body in White Manufacturing of the BMW X6
Markus PfestorfBMW Group
Duane CopelandBMW MC
BMWGroup
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ContentBMWGroup
Body in White Requirements for EfficientDynamics
Body in White Materials
Ultra High Strength Steel Grades
Joining Technologies
Conclusion
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BodyIn
White
EfficientDynamics
Axleand
Kinematics
Power Train
Aero
dyna
mics
Weight and Axle
Load Distribution
Body in White RequirementsEfficient Dynamics
BMWGroup
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- Torsional Stiffness of 29.000Nm/- Implementation of Ultra High Strength Steel Grades- Mixed Material Concept (Steel, Aluminum, Thermoplastic)- Cost Efficient Engineering using existing Panels with a maximum Design
Differentiation
BMWGroup
Body in White RequirementsCost Efficient Light Weight Design
Specific PanelsShared Panels
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BMWGroup
Body in White MaterialsYield Strength
Deep Drawn Steel14%
180 MPa15%
200-220 MPa, 4 %
260 MPa7%
300 MPa18%
380-420 MPa, 25%680 MPa, 5%
950 MPa, 3%
6xxx Aluminum, 2%Others, 4%
550 MPa, 3%
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?
Body-In-White MaterialsAverage Minimum Yield Strength
BMWGroup
3SeriesSedan5Series
7Series
1Series
3Series Sedan
7Series 5Series
5SeriesSports Wagon
3SeriesSports Wagon
5SeriesSports Wagon
3Series Sports W. 3Series Coup
3SeriesCompact
Z4Coup
6Series Coup
3SeriesCoup
Z4
3SeriesConvertible
6Series Convertible
150
200
250
300
350
400
MPa475
500
1994 1996 1998 2000 2002 2004 2006 2008 20102008
Start of Production
A
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a
g
e
m
i
n
.
Y
i
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l
d
S
t
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t
h
R
p
0
,
2
Previous X5
Current X5X6
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Body-In-White MaterialsAverage Thickness
BMWGroup
7Series
5Series
Previous X5
3Series Convertible
Z4
7Series
6Series Convertible
6Series Coup
5Series Sports Wagon
1Series
3Series Sports Wagon
0,9
1,0
1,1
1,2
1,3
1,4
1,5
mm
1,7
1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
Start of Production
A
v
e
r
a
g
e
T
h
i
c
k
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e
s
s
Without Advanced High Strength Steel
Current X5 X6
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t = 1.2 mm
t = 1.4 mm
t = 2.2 mm
t = 1.2 mm
Weight Savings: 2 kg/side(compared to a hot stamped part with a constant thickness)
Thickness (t)
Mechanical Values:Yield Strength Rp0,2: > 950 MPaTensile Strength Rm: > 1300 MPa
UHSS Hot Stamped 22MnB5Side Crash
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BMWGroup
UHSS CP800Rear Crash
Weight Savings for theLongitudinal Rear Member: 4,4 kg
Mechanical Values:Yield Strength Rp0,2: 680 - 830 MPaTensile Strength Rm: 800 - 980 MPaElongation A80: > 10%(Complete Longitudinal rear member
including other steel grades)
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BMWGroup
UHSS CP800Rear Crash of a Prototype
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Tested profile
Specimen after Drop Test
Yield Strength Rp0,2Tensile Strength RmElong. after Fracture A80Thickness
Mech. Properties(as delivered)692 MPa901 MPa11,40,99
Mech. Properties(180C, 60 min.)796 MPa923 MPa10,80,99
118 mm
8
8
m
m
40
80
120
kN
200
D
e
f
o
r
m
a
t
i
o
n
F
o
r
c
e
Deformation Time
157,37 kN (with Bake Hardening Response)155,84 kN (without Bake Hardening Response)
BMWGroup
UHSS CP800Rear Crash
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BMWGroup
Thickness of all Parts: 1,5 mm
UHSS CP800X6 Part Application
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BMWGroup
Phase 1 Phase 2 Phase 3
ab
d
a
c
UHSS CP800Tool Realization Guidelines
Tool Change Content : a) Optimize the release of flange formb) Optimize the draw of the embossmentsc) Increase the radii if necessaryd) Optimize the trim
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Secure the part fastening assembly process in the Prototype Phase. Testing the Series assembly Tools with the Prototype Parts and early
Optimization of the Clamping Technology. Higher Measurement Stability in the BIW.
UHSS CP800Clamping in Body in White
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BMWGroup
Joining TechnologiesMaterials and Joining Technologies
Main Joining Technologies: Resistant Spot Welding (6643 Spot Welds) Adhesive Bonding (116999 mm)
Other Joining Technologies: Self Pierce Riveting (82) Clinching (53) Mig Welding and Brazing (8053 mm) Capacitance Discharge Welding
Adhesive Bonding
Spot Weld
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Local Static StiffnessUpper Control Arm
+ 12%
Static Torsional Stiffness + 2%
Dynamic Stiffness+ 0.1Hz
to+ 0.3Hz
Applied Adhesives
BMWGroup
Joining TechnologiesBenefit of Structural Adhesives
Local Static Transversal Stiffness ofthe Upper Control Arm
Difference of Displacements of theSpring Support with and without Adhesive Application
with Adhesivewithout Adhesive
Benefit on Stiffness
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BMWGroup
Joining TechnologiesAluminum Casted Front Shock Tower
- High Pressure VaccumCasting
- Heat Treated
- Machined
- Cataphoretic Painting
- Bonding (ca. 5.4 m)
- Self Pierce Rivets (82 times)
- PVC Sealant
Supplier Body In White Paint Shop
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52 mm
90 mm
BMWGroup
Joining TechnologiesCapacitance Discharge Welder
Cold Forged partMaterial: C15E2C
Advantages:- More economical Process- Less Weld Splatter- High local connection Stiffness- Smaller amount of Heat introduced in Parts during
the welding Process- No Process induced Material Structure Change.
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Force vs. Distance Relationships:1 Outer projection2 Inner projection
Distance (mm)
Internal Weld Seam Evaluation:- Small Fusion Zone- Small heat induced Zone- Continuous Material Connection
2
1
1,0 mm
200 m
BMWGroup
Joining TechnologiesCapacitance Discharge Welder
F
o
r
c
e
(
k
N
)
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Conclusion
Mixed Material light weight Concept for the Body in White 8% Ultra High Strength Steel Grade 46% Advanced High Strength Steel Grade
Significant Weight Savings by UHSS Hot Formed B- Pillar Reinforcement with tailor rolled Blank CP800 for Longitudinal Rear Member
Capacitance Discharge Welding for Bushings High local stiffness Extreme short Process Time
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Thank You for Your Attention