BMW

Group

Technological Innovations in Body in

White Manufacturing of the BMW X6
Markus Pfestorf
BMW Group
Duane Copeland
BMW MC

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Content

BMW
Group

Body in White Requirements for EfficientDynamics

Body in White Materials
Ultra High Strength Steel Grades
Joining Technologies
Conclusion

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Body in White Requirements

Efficient Dynamics

BMW
Group

Body
In
White

and
e
l
x
A
atics
m
e
Kin

Pow
er T
rain

Ae
ro
dy

le
Ax n
d tio
an bu
ht stri
eig Di
W ad
Lo

na
mi
cs

EfficientDynamics

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Body in White Requirements

Cost Efficient Light Weight Design

BMW
Group

Specific Panels
Shared Panels

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

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Body in White Materials

Yield Strength

BMW
Group

180 MPa
15%

200-220 MPa, 4 %
260 MPa
7%

Deep Drawn Steel

14%
300 MPa
18%
Others, 4%
6xxx Aluminum, 2%

950 MPa, 3%
380-420 MPa, 25%

680 MPa, 5%
550 MPa, 3%

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Body-In-White Materials
Average Minimum Yield Strength

BMW
Group

500
Average min. Yield Strength Rp0,2

475

MPa
400

350
Current X5

X6

3Series Sedan
3Series Sports W.

300

3Series Coup
1Series
6Series Convertible
6Series Coup

3Series
5Series
Sports Wagon 7Series
3Series
5Series
5Series
Z4Coup
Sedan
Z4 Sports Wagon
3Series
200
Previous X5
Compact
3Series
7Series 5Series
Coup
3Series
Sports Wagon
150
Convertible

250

1994

1996

1998

2000

2002

2004

2006

Start of Production

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2008

2010

Body-In-White Materials
Average Thickness

BMW
Group

1,7
mm

3Series Convertible

1,5

Without Z4
Advanced
High Strength
Steel
6Series Convertible

Average Thickness

1,4
1,3

Current X5
6Series Coup

1,2

3Series Sports Wagon

Previous X5

7Series

1,1
5Series

1,0
0,9
1992

X6

5Series Sports Wagon

1Series

7Series

1994

1996

1998

2000

2002

2004

2006

Start of Production

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2008

2010

BMW
Group

UHSS Hot Stamped 22MnB5

Side Crash
Thickness (t)
t = 1.2 mm

t = 2.2 mm

t = 1.4 mm

t = 1.2 mm

Weight Savings: 2 kg/side

(compared to a hot stamped part
with a constant thickness)

Mechanical Values:
Yield Strength Rp0,2: > 950 MPa
Tensile Strength Rm: > 1300 MPa

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UHSS CP800
Rear Crash

BMW
Group

Weight Savings for the

Longitudinal Rear Member:
4,4 kg

(Complete Longitudinal rear member

including other steel grades)

Mechanical Values:
Yield Strength Rp0,2: 680 - 830 MPa
Tensile Strength Rm: 800 - 980 MPa
Elongation A80:
> 10%

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BMW
Group

UHSS CP800
Rear Crash of a Prototype

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UHSS CP800
Rear Crash

Yield Strength Rp0,2

Tensile Strength Rm
Elong. after Fracture A80
Thickness

Mech. Properties
(as delivered)
692 MPa
901 MPa
11,4
0,99

Mech. Properties
(180C, 60 min.)
796 MPa
923 MPa
10,8
0,99

200

Deformation Force

kN

118 mm
88 mm

BMW
Group

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

120
80
40

Deformation Time

Specimen after Drop Test

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BMW
Group

UHSS CP800
X6 Part Application

Thickness of all Parts: 1,5 mm

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UHSS CP800
Tool Realization Guidelines

BMW
Group

d
a

Phase 1

Phase 2

Tool Change Content :

Phase 3

a) Optimize the release of flange form

b) Optimize the draw of the embossments
c) Increase the radii if necessary
d) Optimize the trim

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BMW
Group

UHSS CP800
Clamping in Body in White

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.

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BMW
Group

Joining Technologies
Materials and Joining Technologies

Main Joining Technologies:

Resistant Spot Welding (6643 Spot Welds)
Adhesive Bonding (116999 mm)
Spot Weld

Other Joining Technologies:

Self Pierce Riveting (82)
Clinching (53)
Mig Welding and Brazing (8053 mm)
Capacitance Discharge Welding

Adhesive Bonding

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BMW
Group

Joining Technologies
Benefit of Structural Adhesives

Applied Adhesives

Local Static Stiffness

Upper Control Arm

+ 12%

Static Torsional Stiffness

+ 2%

Dynamic Stiffness

+ 0.1Hz
to
+ 0.3Hz

Benefit on Stiffness

with Adhesive
without Adhesive
Local Static Transversal Stiffness of
the Upper Control Arm

Difference of Displacements of the

Spring Support with and without Adhesive
Application

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BMW
Group

Joining Technologies
Aluminum Casted Front Shock Tower

Supplier

Body In White

- High Pressure Vaccum

Casting

- Bonding (ca. 5.4 m)

- Heat Treated

Paint Shop

- Self Pierce Rivets (82

times)

- Machined
- Cataphoretic Painting

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- PVC Sealant

Joining Technologies
Capacitance Discharge Welder

BMW
Group

Cold Forged part

Material: C15E2C

52 mm
90 mm

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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Joining Technologies
Capacitance Discharge Welder

BMW
Group

1
Force (kN)

1,0 mm

Distance (mm)

Force vs. Distance Relationships: Internal Weld Seam Evaluation:

1 Outer projection
2 Inner projection

- Small Fusion Zone

- Small heat induced Zone
- Continuous Material Connection

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200 m

Conclusion

BMW
Group

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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BMW
Group

Thank You for Your Attention

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