Funded by

InnoMateria 2012

Cologne, 22 Mai 2012 Collins Ntchouzou, Volkswagen AG Alexander Schiebahn, ISF

Funded by Light-eBody Objectives & Design Approach  Development of an innovative multi-material lightweight car body  Intensive use of profiles made from (ultra) high strength steel for the vehicle load bearing structure  Lightweight panels from low density materials (aluminium. plastics. manufacturing technologies and joining technologies  CAE method development to enable a reliable simulation of the material combination and the joining  Life Cycle Analysis investigations C. Ntchouzou. Schiebahn/ InnoMateria 2012 Slide No. 2 22. A.2012 © Light-eBody consortium 2012 .05. metalplastic-hybrids or sandwich material)  Integration of the battery structure in the vehicle structure as load bearing element  Details analysis of the used materials.

05. A. Ntchouzou. 3 22.Funded by Light-eBody Objectives & Design Approach Ultra high strength steel vehicle structure in profile intensive design Lightweight panels from material with low density (aluminium or plastics) Source: Ford C.2012 © Light-eBody consortium 2012 . Schiebahn/ InnoMateria 2012 Load bearing battery structure Slide No.

4 22.Funded by Light-eBody Consortium  Altair Engineering  Böllhoff  Dow  Ford  Fraunhofer LBF  Hydro Aluminium  Institut für Kraftfahrzeuge  Institut für Schweißtechnik & Fügetechnik  Laboratorium für Werkstoff. A.05. Ntchouzou. Schiebahn/ InnoMateria 2012 Slide No.2012 © Light-eBody consortium 2012 .& Fügetechnik  LINDE + WIEMANN  Röchling Automotive  ThyssenKrupp Steel  Volkswagen  Werkzeugmaschinenlabor C.

250 kg large volume (1.2012 © Light-eBody consortium 2012 . A.05. Ntchouzou. Schiebahn/ InnoMateria 2012 Slide No.000/d) C C.Funded by Light-eBody Basic Specifications  Use case:  Seats:  Range:  vmax:  Weight:  Production:  Segment: urban/commute 2+3 > 150 km (NEDC) 150 km/h 1. 5 22.

2012 © Light-eBody consortium 2012 . A. Ntchouzou.05. Schiebahn/ InnoMateria 2012 Slide No.Funded by Light-eBody Topology Optimisation  Load Paths  Determination of material distribution within a specified design space  Objective: minisation of complaince  Constraint: 80% volume reduction Frontal impact IIHS Side impact Global stiffness Load cases Side impact Pole impact FMVSS 301 Rear impact Design space Material distribution C. 6 22.

2012 © Light-eBody consortium 2012 . Schiebahn/ InnoMateria 2012 Slide No.Funded by Light-eBody Materials & manufacturing technologies Materials Manufacturing technologies Casting Rolled forming  Plastics  Aluminium  Magnesium  Steel Form-Blow-Hardening Tailored Tempering Extrusion T3 Technology C. A.05. 7 22. Ntchouzou.

Olfermann. Schiebahn/ InnoMateria 2012 Slide No. A. Ntchouzou. A.Funded by Research in innovative. 8 22.05. high-volume capable joining technologies for multi-material design Examples (1/2):  High-speed bolt joining © LWF © Boellhoff  Spotwelding with elements © LWF  Selfpiercing riveting C. Schiebahn/ InnoMateria 2012 T.2012 © Light-eBody consortium 2012 .

Ntchouzou. A. Schiebahn/ InnoMateria 2012 Slide No. high-volume capable joining technologies for multi-material design Examples (2/2):  Laser beam welding  Indirect spot-welding  Adhesive bonding / hybrid joining with new structural epoxies C. 9 22.Funded by Research in innovative.05.2012 © Light-eBody consortium 2012 .

2012 © Light-eBody consortium 2012 . 10 22. A.05.Funded by Life Cycle Analysis based on ISO 14040 Input Energy Raw materials Production Recycling Use Output Emission Waste C. Ntchouzou. Schiebahn/ InnoMateria 2012 Slide No.

Funded by Conclusions  Topology optimisation was conducted to identify the main load paths  The load bearing structure was split into car body structure and battery structure  Suitable joining techniques for the realisation of this approach are now analysed and developed. 11 22. but the joining remains a big challenge.  The intensive profile design approach is very promising concerning light weight and modularity. C.2012 © Light-eBody consortium 2012 .  CAE methods for the simulation of the joining of the material combination are in development  Development accompanying LCA  The integration of the battery structure as load bearing part of the vehicle structure helps reducing the vehicle weight. Schiebahn/ InnoMateria 2012 Slide No. Ntchouzou.05. A.

Ntchouzou. Schiebahn/ InnoMateria 2012 Slide No. 12 22.“ Gottlieb Daimler. A.2012 © Light-eBody consortium 2012 . Worldwide sold battery electric vehicles in the next decades:> ? Mio.3 Funded by „Innovation“ beginning of the 20th century „ Worldwide demand for motor vehicles will not exceed one million … … solely due to the lack of available drivers. Faith in the future innovation ! C. 1901 Worldwide sold vehicles in 2010: > 60 Mio.05.

Funded by C. Ntchouzou. Schiebahn/ InnoMateria 2012 Slide No.05. A. 13 22.2012 © Light-eBody consortium 2012 .