04 - technological innovations in body in white manufacturing of the bmw x6

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BMW X6

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  • w w w . a u t o s t e e l . o r g

    Technological Innovations in Body in White Manufacturing of the BMW X6

    Markus PfestorfBMW Group

    Duane CopelandBMW MC

    BMWGroup

  • w w w . a u t o s t e e l . o r g

    ContentBMWGroup

    Body in White Requirements for EfficientDynamics

    Body in White Materials

    Ultra High Strength Steel Grades

    Joining Technologies

    Conclusion

  • w w w . a u t o s t e e l . o r g

    BodyIn

    White

    EfficientDynamics

    Axleand

    Kinematics

    Power Train

    Aero

    dyna

    mics

    Weight and Axle

    Load Distribution

    Body in White RequirementsEfficient Dynamics

    BMWGroup

  • w w w . a u t o s t e e l . o r g

    - 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

  • w w w . a u t o s t e e l . o r g

    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%

  • w w w . a u t o s t e e l . o r g

    ?

    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

    v

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    a

    g

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    m

    i

    n

    .

    Y

    i

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    l

    d

    S

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    n

    g

    t

    h

    R

    p

    0

    ,

    2

    Previous X5

    Current X5X6

  • w w w . a u t o s t e e l . o r g

    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

    n

    e

    s

    s

    Without Advanced High Strength Steel

    Current X5 X6

  • w w w . a u t o s t e e l . o r g

    BMWGroup

    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

  • w w w . a u t o s t e e l . o r g

    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)

  • w w w . a u t o s t e e l . o r g

    BMWGroup

    UHSS CP800Rear Crash of a Prototype

  • w w w . a u t o s t e e l . o r g

    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

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    m

    a

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    F

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    Deformation Time

    157,37 kN (with Bake Hardening Response)155,84 kN (without Bake Hardening Response)

    BMWGroup

    UHSS CP800Rear Crash

  • w w w . a u t o s t e e l . o r g

    BMWGroup

    Thickness of all Parts: 1,5 mm

    UHSS CP800X6 Part Application

  • w w w . a u t o s t e e l . o r g

    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

  • w w w . a u t o s t e e l . o r g

    BMWGroup

    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

  • w w w . a u t o s t e e l . o r g

    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

  • w w w . a u t o s t e e l . o r g

    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

  • w w w . a u t o s t e e l . o r g

    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

  • w w w . a u t o s t e e l . o r g

    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.

  • w w w . a u t o s t e e l . o r g

    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

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    e

    (

    k

    N

    )

  • w w w . a u t o s t e e l . o r g

    BMWGroup

    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

  • w w w . a u t o s t e e l . o r g

    BMWGroup

    Thank You for Your Attention