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04 - Technological Innovations in Body in White Manufacturing of The BMW X6 PDF
04 - Technological Innovations in Body in White Manufacturing of The BMW X6 PDF
Group
Markus Pfestorf
BMW Group
Duane Copeland
BMW MC
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BMW Content
Group
Joining Technologies
Conclusion
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BMW Body in White Requirements
Group
Efficient Dynamics
Body
In
White
Pow
er T x le and
rain A
em atics
Kin
EfficientDynamics
W ad
cs
Lo
eig Di
mi
ht stri
na
an bu
dy
d tio
ro
Ax n
Ae
le
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BMW Body in White Requirements
Group
Cost Efficient Light Weight Design
Specific Panels
Shared Panels
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BMW Body in White Materials
Group
Yield Strength
300 MPa
18%
Others, 4%
6xxx Aluminum, 2%
950 MPa, 3%
680 MPa, 5% 380-420 MPa, 25%
550 MPa, 3%
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BMW Body-In-White Materials
Group
Average Minimum Yield Strength
500
475
MPa
Average min. Yield Strength Rp0,2
400
350
300
3Series
3Series Sedan
3Series Sports W.
Current X5
1Series
?X6
3Series Coup
6Series Convertible
250 Sports Wagon 7Series
5Series
6Series Coup
3Series
5Series Sedan 5Series Z4Coup
Z4 Sports Wagon
200 Previous X5
3Series
3Series Compact
7Series 5Series Coup
Sports Wagon 3Series
150 Convertible
Start of Production
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BMW Body-In-White Materials
Group
Average Thickness
1,7
mm
3Series Convertible
1,5
1,4 Without Z4
Advanced
High Strength Steel
Average Thickness
6Series Convertible
1,3 Current X5
6Series Coup
X6
1,2 Previous X5
3Series Sports Wagon
7Series
1,1 5Series Sports Wagon
5Series 1Series
1,0 7Series
0,9
1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
Start of Production
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BMW UHSS Hot Stamped 22MnB5
Group
Side Crash
Thickness (t)
t = 1.2 mm
t = 2.2 mm
Mechanical Values:
t = 1.2 mm Yield Strength Rp0,2: > 950 MPa
Tensile Strength Rm: > 1300 MPa
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BMW UHSS CP800
Group
Rear Crash
Mechanical Values:
Yield Strength Rp0,2: 680 - 830 MPa
Tensile Strength Rm: 800 - 980 MPa
Elongation A80: > 10%
(Complete Longitudinal rear member
including other steel grades)
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BMW UHSS CP800
Group
Rear Crash of a Prototype
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BMW UHSS CP800
Group
Rear Crash
118 mm
Mech. Properties Mech. Properties
(as delivered) (180C, 60 min.)
88 mm
Yield Strength Rp0,2 692 MPa 796 MPa
Tensile Strength Rm 901 MPa 923 MPa
Elong. after Fracture A80 11,4 10,8
Thickness 0,99 0,99
200
Tested profile
157,37 kN (with Bake Hardening Response)
kN
155,84 kN (without Bake Hardening Response)
Deformation Force
120
80
40
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BMW UHSS CP800
Group
X6 Part Application
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BMW UHSS CP800
Group
Tool Realization Guidelines
a a
b
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BMW UHSS CP800
Group
Clamping in Body in White
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BMW Joining Technologies
Group
Materials and Joining Technologies
Adhesive Bonding
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BMW Joining Technologies
Group
Benefit of Structural Adhesives
Local Static Stiffness
+ 12%
Upper Control Arm
Static Torsional Stiffness + 2%
+ 0.1Hz
Dynamic Stiffness to
+ 0.3Hz
Applied Adhesives Benefit on Stiffness
with Adhesive
without Adhesive
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BMW Joining Technologies
Group
Aluminum Casted Front Shock Tower
Supplier Body In White Paint Shop
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BMW Joining Technologies
Group
Capacitance Discharge Welder
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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BMW Joining Technologies
Group
Capacitance Discharge Welder
1
1,0 mm
Force (kN)
Distance (mm)
200 m
Force vs. Distance Relationships: Internal Weld Seam Evaluation:
1 Outer projection - Small Fusion Zone
2 Inner projection - Small heat induced Zone
- Continuous Material Connection
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BMW Conclusion
Group
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BMW
Group
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