2 vehicle development process & para metrical car body design_ii
TRANSCRIPT
Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen
Vehicle Body Engineering
Stechert, C. und Nehuis, F. ; Friday, October 01, 2010
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 2
Agenda
1. Motivation
Vehicle history
Vehicle environment
2. Inauguration
Requirements (vehicle and car body)
Car concepts
3. Vehicle Development Process
Goal definitions
Costs
Materials
Manufacturing processes
4. Parametric Car Body Design
Tools and requirement
Virtual reality
5. Design Attributes
Package
Design
Light weight constructions
Noise vibration harshness
Modularisation
Safety
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 3
[Adam Opel AG]
1912: single production with flexible “model mix“
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 4
1927: implementation of assembly lines
[Adam Opel AG]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 5
Vehicle production today - (fully) automated assembly line
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 6
Manufacturing costs by vehicle areas
[H. Lorenz: “Die Entwicklung des Energieverbrauches in den Werken”, Volkswagen AG, 2003]
Analysis of the shares of expenses for energy use
(approximate quantifying)
Fahrwerk
15%
Ausstattung
25%
Elektrik
10%
Karosserie inkl.
Lack
30%
Motor &
Getriebe
20%
Karosserie inkl. Lack
Fahrwerk
Motor+ Getriebe
Ausstattung
Elektrik
Verteilung des gesamten Primär-Energiebedarfes
WerkstoffBenzin Herstellung
Nutzungsphase
VW-Anteil
Entsorgung
Car body
including paint
30%
Underbody
15%
Electrical
equipment
10%
Equipment
components
25%
Engine &
Transmission
20%
VW shareGasoline production Material
Disposal
Utilisation phase
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 7
Body Production Process
[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60. Geburtstages
von Prof. Dr.-Ing- H.-J. Franke, Braunschweig, 2004]
Manufacture
of
components
Body
construction
Cataphoretic
painting
sealing
assembly
Logistics-processes
The choice of construction and the material has an impact on the resulting
process chain
Purchase
Semi-finished
products
• Sheets
• Plates
• Profiles,
• …
• Stamping
• Pressing
• Deep drawing,
• …
• Mechanical
joining methods
• QS, …
• Thermal and
mechanical joining
methods, ...
• Sealing
• Painting
• …
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 8
Shell construction
Shell-monocoque construction
Frame- Monocoque construction
Shell- frame-monocoque construction
concept
Shell
construction
Monocoque
construction
Frame
mode of
construction
Scheme for optimized body production
[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60. Geburtstages von Prof. Dr.-Ing- H.-J. Franke,
Braunschweig, 2004]
Technical criteria
Technological
criteria
Economic criteria
Logistics-processes
Manufacture of
componentes
Body
construction
Cataphoretic
painting, sealing Assembly
Purchase
Semi-finished
products
Technology catalogues
Pro
duction
Evalu
ation a
nd V
ariation 1st step
Selection of the general
construction
2nd step (a)
Intermediate substitution
2nd Step (b)
Quantifying of the component
production
3rd Step
Quantifying of the joining
tasks
4th step
Evaluation Process Steps
Optimized concept
for the supporting
structure
Main
com
ponents
ggf. Radhäuser innen
Kotflügel (r,l)Federbeinaufnahmen
Bodenwanne
Längsträger hinten
Hinter-wagen
Trennwand hinten
Bodenbleche
Trennwand vorn
Schweller (Längsträger) Dachfläche
Dachrahmen
Querträger hinten C-Säule außen
C-Säule
D-Säule
Sitzquerträger hinten B-Säule außen
B-Säule
Sitzquerträger vorn A-Säule außen
A-Säule
Querträger vorn
Fahrgast-zelle
Stoßfängerquerträger
Kotflügel (r,l)
Federbeinaufnahmen
Längsträger
Vorder-wagen
AußenhautTragstrukturBoden, Chassis
Radhausträger
Radhausträger
Without doors and hatches
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 9
Optimization of the process run - bodywork and painting
[H. Timm: „Kostenattraktiver Leichtbau“, Werkstofftag Volkswagen AG, Wolfsburg, 2003]
Rolling mill Pressing plant
Degreasing +
conversion Bodywork
Production of
the pressed
parts
Pre-treatment + cataphoretic painting
Separate
heat
treatment
Finish
Rolling mill Pressing plant
Production of
the pressed
parts
Bodywork Pre-treatment + cataphoretic painting
Paint-spray line
Manufacturing process Audi A8 (D2)
Manufacturing process Audi A8 (D3)
Space frame
and attaching
parts
Degreasing Cataphoretic
painting
Drying
20 min at
200°C
Degreasing Cataphoretic
painting
Drying
20 min at
>185°C
FinishSpace frame
and attaching
parts
1 Dry
lubrication
1 Conversion
2 Dry
lubrication
Paint-spray line
1
1
2
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 10
Process flow - space frame with plastic sheeting
[Volkswagen AG, Konzernforschung, 2001]
Profile bending/
forming
Complete the
frame
Sheets on
accumulative
skid
Modules to the base frame
Injection
molding of the
outer parts
Press
sheets
Add profiles to
the framework
Roof paint-spray
line
Painted component parts
to module assembly
areas
Base frame
assembly
Module
assembly
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 11
Semi-finished products-manufacturing technologies of
Al-space frames
[Projekt Faszination Karosseriebau]
Formed metal parts
Cast components
Extruded profiles
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 12
Vehicle Body Engineering
Vehicle Development Process
Manufacturing Processes
(state-of-the-art)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 13
Existing & theoretically possible structural concepts
Applied and new methods of component manufacture and assembly
Technology Catalogue
[R. Hohmann: „Systematische Analyse und Machbarkeitsstudie von Karosseriekonzepten für eine
wirtschaftliche Kleinserienfertigung“, Diplomarbeit Inst. f. Konstruktionstechnik, TU Braunschweig, 2003]
Vehicle concept
construction matrix
Technology
catalogues
Concept tree
structure concepts
Vehicle concept
Target market
Customer group
Investments
Direction of
optmization, …
Quantifying &
Selection
Luxury vehicle
Small quantities
Cost-cutting
Time, Supplies
...
Application optimized structure concept
Delivery
conditions
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 14
Technology catalogues - Excerpt from a sample
[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60. Geburtstagesvon
Prof. Dr.-Ing- H.-J. Franke, Braunschweig, 2004]
-solution catalog
- Classification
- Technical criteria
- Technological criteria
- Economical criteria
-Evaluation and weighting of the
procedure on quantity
Technology catalogue thermal joining methods
}
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 15
Overview of advanced manufacturing technologies
Patchwork technology
Thin wall steel casting
Multifunctional large castings
Colored plastic film
Tailor Rolled Blanks
IHU
Extruding
…
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 16
Examples of advanced manufacturing technologies
[Th. Krusche: "Stahl - Neuere Entwicklungen für den Karosseriebau", Werkstofftag Volkswagen AG, Wolfsburg, 2001]
Thin wall steel casting
• Local thickness differentiation
Weight reduction
• Cost advantage over welded
circuit boards
• Local thickness differentiation
Weight reduction
• Component integration
Patchwork technology
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 17
Multifunctional casting – middle water tank
[H. Timm: „Kostenattraktiver Leichtbau“, Werkstofftag Volkswagen AG, Wolfsburg, 2003]
Audi A8 (D2)
7 components: 5554 g
Audi A8 (D3)
4 components: 3742 g
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 18
Development of multifunctional castings
[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher
IIR-Werkstoffkongress 2001. Stuttgart, 2001]
Components: 6
Mass : 4180gComponents: 1
Mass: 2300 g
High-Q-casting
Permanent mold
castings parts
Profile
Sheet
1150 1220
Pillar B Audi A8 (D2) Pillar B Audi A2ASF®
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 19
Shell construction / deep drawing
[Volkswagen AG, Entwicklung Karosseriestruktur E1 und Korrosionsschutz, 2005]
Example Passat B6
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 20
Colored plastic film
[H. Lorenz: “Die Entwicklung des Energieverbrauches in den Werken”, Volkswagen AG, 2003]
Preheating
Vacuum
Material for core-back
injection molding
Deep-drawn, colored foil
back injection molding
deep-drawn, colored foilColored foil
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 21
Examples of advanced manufacturing technologies - Tailored
Blanks
[N.N.]
Laser welded inner door panel
Laser weld
Laser welded wheel arch
Conventional differential design
(spot welding)
Integral „Tailored Blanks“
Laser weld
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 22
Variable wall thickness
[Th. Krusche, "Flexibles Dickenwalzen", Volkswagen AG, 2000 ]
• Increases: 1:40 to 1:1000
• Continuous process
• No welds
Lightweight Technology
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 23
Production and properties of flexible rolled sheet metal
[C.-M. Honsel: "Entwicklung eines Crash Management Systemens (CMS) aus hochfest flexibel
gewalzten Stählen", VP Business Development, Magna Cosma, VW TechShow, Wolfsburg, 2004]
Stress distribution:
Weld vs. sheet metal thickness transition
Checking of the deep drawing
Quelle: RWTH Aachen, Institut für Bildsame Formgebung
• Consistent sheet thickness
• Harmonic stress distribution in the sheet
thickness
• Uniform surface
• No notching effects
• No structural damage by welding
• Easily deformable
The material and forming
characteristics of flexible and
conventionally rolled sheets are
comparable
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 24
Component Examples
[P. Böhlke, "Übersicht Flexibles Walzen", Institut für Bildsame Formgebung der RWTH Aachen, 2002]
Sheet thickness1,60mm / 2,60mm / 1,40mm
Sheet thickness 2,00mm / 1,20mm / 2,00mm
Car body part (longitudinal chassis beam)
Car body part (cross beam)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 25
Applications of TRB in the body structure
[C.-M. Honsel: "Entwicklung eines Crash Management Systemens (CMS) aus hochfest flexibel
gewalzten Stählen", VP Business Development, Magna Cosma, VW TechShow, Wolfsburg, 2004]
Cross beam rear seat
left/ right
2,0mm – 1,4mm –
2,0mm
ZStE 250/300 TRB Z100
Cross beam front seat
left/ right
2,0mm – 1,4mm –
2,0mm
ZStE 250/300 TRB Z100
longitudinal chassis
beam SGS
1,8mm – 2,8mm –
1,8mm
ZStE 250/300 TRB Z100
Heel support
1,2mm – 0,7mm –
1,2mm
ZStE 420 TRB Z100
Achieved improvements:
• Improved side impact behavior
• Parts reduction 19-7
• Realized cost savings potential
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 26
Closed profiles - Enlargement of TRB-technology
[P. Böhlke, "Übersicht Flexibles Walzen", Institut für Bildsame Formgebung der RWTH Aachen,
2002]
Profiles adjusted to forces Crash-Boxes
IHU-components
0,80mm
1,00mm
1,20mm
0,70mm
1,40mm
0,80mm
0,80mm
1,40mm
TRB-production processes
· Deep drawing
· Stretch drawing
· IHU
· Bending
· …
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 27
BMBF – Joint Research Project HIPAT
Objective: Accelerating the development and market launch of a new generation of
light weight profiles by roll forming high-strength tailor rolled blanks
Development DP-Steel (Salzgitter Mannesmann Forschung)
Tailor rolling(Muhr und Bender)
Roll forming(Welser)
Application(Schmitz
Cargobull)
Process development(PTU Darmstadt)
Design methodology (IK)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 28
ClassificationMain
partAccess part
By cross
section / profile
3D-
model,
standar-
dized
Modular functions
Further
access
features
BMBF – Joint Research Project HIPAT
Objective: Accelerating the development and market launch of a new generation of light
weight profiles by roll forming high-strength tailor rolled blanks
Function-oriented object catalogue with HI-PAT profiles
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 29
Internal high pressure forming (Hydroforming)
[P. Richard, Firmenpräsentation UGINE, Wolfsburg, 2001]
Hydroformed 304 member
Porsche Boxter
Th.2.4mm - Dia 38mm
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 30
Hot Air Expansion Technology - Forming of hollows
[HEATform GmbH, www.HEATform.com]
Air
pressure
Thermal element
1) The insertion of the tube 2) Commencement of moulding
3) End of the axial forming 4) End of the calibration
axial
force
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 31
Internal high pressure forming (Hydroforming)
[P. Richard, Firmenpräsentation UGINE, Wolfsburg, 2001]
Inside : HF
seamweld
behaviour
Hydroformed
304 stainless steel node
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 32
Hydroformed side roof frame, 3D curved
[H. Timm: „Kostenattraktiver Leichtbau“, Werkstofftag Volkswagen AG, Wolfsburg, 2003]
AA
B
B
C
C
A-A
B-B
C-C
Roof frame overall length :
Wall thickness:
3000 mm
4,5 mm
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 33
Internal high pressure forming structure – rear longitudinal
chassis beam
[Th. Krusche, H.Walter, K.-U.Dudziak:"Untersuchung und Erprobung einer Stahl-Spaceframe-Struktur aus Innenhochdruck umgeformten
und rollprofilierten Bauteilen",FB P367 Studiengesellschaft Stahlanwendung. Düsseldorf, 2000]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 34
Behavior of a hydroformed component in side crash
[Th. Krusche, R. Koschorrek: "Konstruktionsmethodik und Karosseriekonzepte", Symposium anlässlich des 60.
Geburtstages von Prof. Dr.-Ing- H.-J. Franke, Braunschweig, 2004] Y intrusions at 60 ms [mm]
Hydroformed B-pillar with extruded sill
(2.5 mm aluminum 8.0 kg per side)
Roof frame
B-pillar
sillboard
B-pillar at the shell construction
(steel)
Crash Gain
Hinge-joint reinforcement of
the B-pillar on the bottom
Adjustable safety belt
Holder interior lining
Reinforcement
Adjustable B-pillar
inside (not shown)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 35
Combined forming operations of a roof frame
Roof frame:
Challenge: Adjusting the roll profile to the given distribution and the given cross sections
Solution in cooperation with Wagon:
Roll profiles:
• Front embossed
• Rear widened
• Stretch bending
• possible necessary stamping operation
Nevertheless: significantly cheaper than IHU
stretch bending
compressed
widened
Fzg. p.a.
Fertigungs-
kosten
(abzügl
Material)
Werkzeug-
kosten Invest
IHU 30000 100% 100% 100%
IHU 60000 97,60% 100% 100%
Streckbiegen 30000 75,40% 106% 24%
Streckbiegen 60000 73% 106% 24%
Vehicles p.a.
Manufactur-
ing costs
(less
material) Tool costs Invest
Stretch bending
IHU
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 36
Combined forming operations of a roof frame
In integrated steps, the embossed profile is
bent and stretched into the desired shape
for the final part.
Then, cut or punch operations can be
performed on the the flange.
Proposal of "Wagon" for a roof frame:
• Roll profile
o rear widened
o front embossed
o subsequent stretch bending
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 37
Extrusions
[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher IIR-
Werkstoffkongress 2001. Stuttgart, 2001]
Phases of the manufacturing process
Extrusion and
trimming
Hydro calibration Finishing
conditioning
Die
Dummy block
Pick-up Die plate Profile
Filling
system
Profile
perforate, final cut
Component cleaning/
surface conditioning
Artificial aging to
increase the strength
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 38
Extrusions
[Projekt „Faszination Karosseriebau“]
Using the example of
extruded profiles of the
undercarriage from the
project "Fascinating
body construction"
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 39
Vehicle Body Engineering
Vehicle Development Process
Manufacturing Processes
(Joining Technology)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 40
Construction method -joining systems
[Volkswagen AG, Konzernforschung, 2001]
Metallic Mixed construction FRP / composite construction Modular construction
• Resistance soldering,
(MIG) brazing, bonding
and mechanical joining
of Al / St, and Mg / Al
• Welding, adhesive
bonding and mechanical
joining of stainless steel
structures
• Joining in the assembly
• Joining of surface-refined
components
• Structural joining of
FKV-St/-Al/-Mg
(Mechanical joining and
bonding)
• Design and
investigation plan for
-problem
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 41
Joining technology for new constructions
[Volkswagen AG, Konzernforschung, 2001]
Metallic mixed construction
FRP / composite construction
Modular construction
Cost-effective and functionally light vehicle structures
Extension of existing process limitations
Building-specific redevelopment
Welding
Brazing
Mechanical Joining
Bonding
Hybrid Joining
High-strength
steel
Stainless steel
Aluminium
Magnesium
FPC
Active fluid mediabased forming
Roll profiling
Extruding
Castingtechnologies
Injection/ pressingtechniques
Objective:
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 42
Joints design
[Volkswagen AG, Konzernforschung, 2001]
Use of additional elementsPlug solutions
Welding solutions
Quelle: JüttnerQuelle: Meschut
Quelle: TKS
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 43
Schematic structure of the body skin structure –
A/A0 segment state Golf IV
[Th. Krusche, "Projekt Faszination Karosseriebau", Volkswagen AG, Konzernforschung, 2004]
Chassis IGeo station
welding
Chassis IIGeo station
welding
Side partsGeo station
welding
RoofGeo station
welding
Attaching
parts
• Used joining techniques:
- Spot welding
- MIG/MAG
- Laser welding
- Bonding
- …
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 44
Joining techniques - VW Passat
[H. Friedrich, H.-G. Haldenwanger: "Leichtbaustrategien und Trends: Wettbewerb der Bauweisen und Werkstoffe", Bad Homburg, 2001]
High-strength sheet metal
Bonds
Laser seam
Platinum Technology
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 45
Laser welding
[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher IIR-Werkstoffkongress 2001.
Stuttgart, 2001]
Laser welding
Laser welded seam
Advantages of laser welding:
• Linear welded seam
• Low flange width at lap joints
• Unilateral accessibility by
deep-weld effect
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 46
Seamless connection with laser soldering
[Volkswagen AG, Entwicklung Karosseriestruktur, 2002]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 47
Punch rivettings
[H. Engelhard: "Der Einsatz von Aluminium im Karosserie-Rohbau am Beispiel des ASF® der 2. Generation des Audi A2", 2. Deutscher IIR-Werkstoffkongress 2001. Stuttgart, 2001]
Punch rivettings
Punch rivetting connection
at the rear end plate
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 48
Elastic bonding with the roof assembly
[J. Wieschermann, A. Starlinger: "Über den Einsatz von Hybridbauweisen im modernen Schienenfahrzeug- und Busbau", Leichtbau-Symposium Dresden, 2002]
Aluminium layer
Aluminium layer
Foam core
Aluminium profile with C-bar
Elastic glue joint
Elastic glue joint
Aluminium
roof frame
Gasket
Spacer
Beading edge
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 49
Vehicle Body Engineering
Vehicle Development Process
Manufacturing Processes
(Corrosion Prevention and Paint)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 50
Corrosion protection at Volkswagen
Road salt induced
corrosionAtmospheric
corrosionAir temperature, air
humidity, air pollution
Dynamic vehicle
load
Damage to surface coatings
and waterproofing
Blunting means
Gritt, chippings,
granules
Dirt deposits
Splashing water, mud
and salts
Freezing rain
Cracks in the corrosion
protection through ice
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 51
High mountainareas
Summer:warm, wetWinter:cold, dry
Summer:warm, wetWinter:very cold, dry
Summer:cold, dryWinter:very cold, dry
Summer:medium, wetWinter:medium, wet
Summer:warm, dryWinter:medium, wet
Summer: warm, dryWinter:cold, dry
Summer:warm, dryWinter:medium, dry
Summer:very hot, humidWinter:hot, humid
Summer: hot, humidWinter:Hot, dry
Humidity
Water
Heat
T (°C)
Solar radiation
Cold, ice,
snow
Ozone O3
Salt
Climates and weathering conditions
[Volkswagen AG]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 52
Corrosion protection in the development
Task: to ensure fulfillment of this guarantee even in the setting of development design,
materials and manufacturing technology, so that corrosion can be prevented / reduced
Seam sealing
Underbody protection
Cladding and structural
corrosion protection
zinced
Paint system Wax conservation
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 53
Corrosion protection measures for the VW Golf 6:
Galvanised body
Lacquer coat design based on the process 5a
Rough seam sealing, fine seam sealing
Cap
PVC coating
Cavity protection
Attachments to the underbody
Corrosion protection on the example of the Golf VI
[Volkswagen AG]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 54
Seam sealing
[Volkswagen AG]
Rough seam sealingon the example of the front wheel
arch
Fine seam sealingto the attachments
Inner sheet
Outer sheet
Fine seam sealing
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 55
Plugs and PVC underbody
[Volkswagen AG]
Cap on the example underbody
Car body
Plug
Installation situation:
PVC-coating on sills
Stone chip protection sill
Abrasion protection for
KU rear wheel house
(will be applied from the
inside)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 56
Underbody protection, preservation of hollow spaces
Rear wheel
arch shell (KU)
Cw- gound cover (KU)
Front wheel arch
shell (KU)
Motor casing (KU)
Heat shield plates (aluminum) also
undertake stone-chipping protective
function
Tank undertakes stone-
chipping protective
function
Attachments - Underbody protection Preservations of hollow spaces
Preservation of hollow spaces by
wax flooding the hollow spaces
(sills, rails, etc.)
Preservation of the lower door groove
either by wax flooding or by manual
spraying of wax
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 57
Surface protection and paint system
[H. Lorenz: “Die Entwicklung des Energieverbrauches in den Werken”, Volkswagen AG, 2003]
Zinc layer 7µm-10µm
Phosphate layer 3µm
Cathodic dipping paint 20µm
Filler 30µm
Base coat paint up to 20µm
Clear paint up to 40µm
Flood wax <500µm
Chromophore
periphery
Measures for corrosion
protectionSteel
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 58
Drying parameters
[H. Lorenz: “Die Entwicklung des Energieverbrauches in den Werken”, Volkswagen AG, 2003]
HRK
Decklack
Basislack
Waschen
Füller
KTL
0
20
40
60
80
100
120
140
160
180
200
Temperature in °C
40min. 20 min. 20 min. 5 min. 30 min.
5min.
Drying times
Cooling to about 35 ° C for further
processing
Filler
Wash Base
coat
paint
Roof paint
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 59
Agenda
1. Motivation
Vehicle history
Vehicle environment
2. Inauguration
Requirements (vehicle and car body)
Car concepts
3. Vehicle Development Process
Goal definitions
Costs
Materials
Manufacturing processes
4. Parametric Car Body Design
Tools and requirement
Virtual reality
5. Design Attributes
Package
Design
Light weight constructions
Noise vibration harshness
Modularisation
Safety
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 60
Special need for theoretical investigations in the form of simulation calculations early in the
development of the vehicle or the body, when no parts are available for testing. In particular,
the computational procedure can be divided into two groups:
• Investigations of the entire vehicle
• Investigations of sub-systems
For the conception and the design of the body, both methods are used.
The aim is to define the design through numerical simulation.
IT, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 61
Simplified FE-body model
a-z: brackets
1-7: nodes
Metal surfaces are not shown
Simplified FE model car
Total vehicle, see also CAE lecture.
IT, models and tools, static and dynamic
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 62
Detailed FE-body model
IT, models and tools, static and dynamic
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 63
Steps of the component design
[Audi AG: "Schritte der Bauteilgestaltung"]
Definition of the component geometry in the
constructional system environment
Analysis component requirements profile Material selection
pre-dimensioning
Primary data (scores)
Secondary data
(features)
Component calculation CAE
structural analysis
- Stiffness/ stability
- Static-dynamic stability
- Vibration analysis
- Durability analysis
CAD design component geometry
Adjustment (iterative)
Plastics: rheological calculation by 2D-3D-CAD/CAE (Cadmould, Moldflow, ...)
Metals: shape completion and solidification simulation (Magma, ProCast, Simtec, Simulor...)
Adjustment (iterative)
Tool design with CAD / CAE (geometry, rheology, heat balance, strength ...)
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 64
FlexBody – Application for Modular Vehicle Structures
Examples for FlexBody structures
4-Seat Compact Sports Car (Capro) 6-Seat Compact Van (FunVan)
Source: Imperia GmbH
The aim of this project is to develop a procedure that generates a cost-effective car body
using body-on-frame construction based on an intelligent modular construction system
within the shortest development and construction period possible.
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 65
FlexBody – Application for Modular Vehicle Structures
2 … 5-arm-joints
Standardisation of body joints
Increase in units
Reducing parts costs
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 66
Overview of CAE (calculation method) - not FEM - rigid body mechanisms
Source: AGELIDIS, N.: 3-D Crash Analysis using ADAMS
SAE-Paper 885076, 1988
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 67
Overview of CAE (calculation method) - not FEM - First Order Analysis
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 68
Overview of CAE (calculation method) - Finite element method
3102
m
kg
T
BIWNmAC
m Analytical formalism low informational value
highest level of abstraction
extensive data collection
Spring-mass model low informational value
high level of abstraction
difficult data collection
Rod model moderate informational value
(FE-rod model) high level of abstraction
moderately difficult data collection
Shells / bar hybrid model good informational value
(FE-shell / beam) medium level of abstraction
simple data collection
automatic coupling possible
Shell/ bar hybrid model best informational value
Realistic components low level of abstraction
(FE-Shell/ beam) simpliest data collection
automatic coupling possible
FE
M m
od
els
Oth
er
mo
de
ls
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 69
• The finite element method has been able to push through since the early days - about 1960 –
as a very adaptive numerical method
• It was developed with the advent of the computer systems of classical structural analysis and
is used in almost all engineering applications
• The importance of the method is based on the uniform approach to various problems
• Basically, it is always the same solution approach for a two-or three-dimensional structure
• Complex structures can firstly be built with this method
• However, the finite element method (FEM) is an approximation method!
Calculation methods, computer tools, models and tools - finite element methods - Summary
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 70
• Unique simulation models for all modes
• Major components for frontal impact
P/T assembly
wheel and chassis assembly
instrument panel
fuel system
load cases (i.e. barrier types, dummies etc.)
• Manual assembly process
time inefficient
error sensitive
no update compatibility
Radioss Simulation
Model
Frontal Impact Crash Model
Frontal Impact Crash Components
Finite element method - Crash Simulation – Overview model assembly and simulation chain
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 71
Active include files example: P/T and P/T mounts only
Model components in pre processor
Finite element methodsCrash simulation – Overview – Module
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 72
Today:
> 1.000.000 Elements
Finite element methodsCrash simulation – Overview
Year
Development of models for the frontal crash
Model S
ize &
Com
ple
xity
300000 elements
80000 elements
6000 elements
500
elements
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 73
t = 60 ms t = 120 ms
Finite element methodsCrash simulation – Overview
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 74
Overview of CAE (calculation method) - Finite element method
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 75
Overview of CAE (calculation method) - Finite element method
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 76
Overview of CAE (calculation method) - rigid body simulation
15ms after TTF
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 77
Overview of CAE (calculation method) - rigid body simulation
Calculation methods, computer tools, models and tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 78
SFE Concept – A Tool for Fast Parametric Engineering Design
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 79
SFE Concept – A Tool for Fast Parametric Engineering Design
Rapid prototyping: Quick, easy and
accurate topology & geometry model
creation for with design constraints
Implicit parameterization “NO” additional
time for parameterization
Easy model variation
Integrated Finite Element Generator
Store models and components in library for
generation of knowledge database and
reusability
Shape & size optimization in closed batch
loop
On-the-fly definition of design variables and
design space
Integration of specific applications like
commercial optimization and design tools
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 80
Agenda
1. Motivation
Vehicle history
Vehicle environment
2. Inauguration
Requirements (vehicle and car body)
Car concepts
3. Vehicle Development Process
Goal definitions
Costs
Materials
Manufacturing processes
4. Parametric Car Body Design
Tools and requirement
Virtual reality
5. Design Attributes
Package
Design
Light weight constructions
Noise vibration harshness
Modularisation
Safety
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 81
Virtual Technologies - Definition
■ Virtual reality VR = real-time applications
■ Augmented Reality AR = Mixed Mock-Ups in real time
■ Digital Mock-Up DMU = data bases and application programs
■ Calculation / simulation, for example finite elements, fluid flows, etc.
realvirtual
Source :Audi EK
Virtual Reality Reality
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
Augmented Reality
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 82
Objectives
Acceleration of the development process
Frontloading
Software rather than hardware, "look before you build“
Increased quality
Identification of problems in early stages
Improvement in prototype quality / production quality
Verification of all options or derivatives
Simple verification of manufacturability and operation
Cost reduction
Reduction of development time and time-to-market
Reduction of models and prototypes
Lowering of the modification effort
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 83
Innovation in the development process
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
Virtual box seat Ergonomics Simulation Virtual Vehicle
Concept Development Series Development Series Preparation
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 84
Virtual cockpit
Virtual driver‘s seat:
model of the interior of a vehicle
Clearance distance
Visibility inside, outside
Sense of space
Reachability
Representation of real and planned components
Simple representation of variants and derivatives
Very early use in the development process
Cost and time savings
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 85
Ergonomics
Insertion of people in the virtual scene
Intuitive interaction with the scene
Analysis of operating concepts
Ergonomics analysis
Simple representation of
variants and derivatives
Analysis of different body
measurements of the user
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 86
Simulation
Representation of stresses
Assembly of hoses
Installation of cables and connectors
„Design in the loop“
Preliminary design
Simulation of, for example, deflections
Reduction of development iterations
Higher quality in preliminary design stage
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 87
Virtual vehicle
Real-time calculations
Light
Reflections
Shades
Realistic and dependable illustration
Quantifying of the appearance of the vehicle
Illustration
Different colors
Complete Vehicles
Quicker preparation of design decisions
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
Comparison
real - virtual
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 88
Product-related innovations
Concept Development Series Development Series Preparation
Virtual
assembly
Robot programming
Analysis of
Interference
Virtual Seating Buck
Ergonomics
Simulation
Virtual vehicle
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 89
Virtual assembly
Determination of assembly sequences
Reachability of the workspaces
Easy part fits
Usability of tools
Ergonomics analysis
Posture
Load
Collisions
Early confirmation of the preliminary design
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 90
Analysis of Interference
Representation of plans in
real environment
New products
New equipment
Safety
Safe and easy planning of new
production facilities
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]
1 October 2010 | Stechert, C. and Nehuis, F. | Vehicle Body Engineering | Page 91
Robot programming
Representation
Paths of motion
Coordinate systems
Interference check of virtual paths
Manipulation of virtual paths
Staff training
Avoiding of errors in the processes
[W. Schreiber: "Visualization Techniques to Accelerate Product Development", Volkswagen AG, 2005]