VD - Part 12 - Automotive Materials and Production Techniques

VEHICLE DESIGN
&
CAD
Işık University - AUE 421
Week #12
Atabay - Istanbul Technical University 1

Today ?
Automotive Materials and Production

Introduction

Unitary and Chassis Body
architecture
Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Land Rover Freelander with
monocoque body

Loads
Reference: Hodkinson, R.., Fenton, J., Lightweight electric/hybrid vehicle design, Butterworth-Heinemann, 2001.
Loads - Inertial loading
Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Static proof loading

Impact proof loading

Automotive (Body) Materials

Requirements of different panels
comprising the BIW structure

High Strength Steels
HSS : High strength steel, more commonly referred to as high-strength low-

alloy steel (HSLA steel), a type of steel with high yield and tensile strength.
High-strength low-alloy steel (HSLA) is a type of alloy steel that provides better
mechanical properties or greater resistance to corrosion than carbon steel.
HSLA steels vary from other steels in that they are not made to meet a specific
chemical composition but rather to specific mechanical properties. They have a
carbon content between 0.05–0.25% to retain formability and weldability. Other
alloying elements include up to 2.0% manganese and small quantities of
copper, nickel, niobium, nitrogen, vanadium, chromium, molybdenum, titanium,
calcium, rare earth elements, or zirconium.

Hydroforming
HT = hydroformed tube
HS = hydroformed sheet
Hydroforming is a cost-effective way of shaping
ductile metals such as aluminum, brass, low alloy
steels, stainless steel into lightweight, structurally stiff
and strong pieces. One of the largest applications of
hydroforming is the automotive industry, which makes
use of the complex shapes possible by hydroforming
to produce stronger, lighter, and more rigid unibody
structures for vehicles. This technique is particularly
popular with the high-end sports car industry and is
also frequently employed in the shaping of aluminium
tubes for bicycle frames. Hydroforming is a
specialized type of die forming that uses a high
pressure hydraulic fluid to press room temperature
working material into a die.

Hydroforming

Bake Hardened Steels
The composition and processing of these

steels are designed to promote a
significant increase in yield strength
during low-temperature heat treatment,
particularly paint curing.
Reference: http://automotive.arcelormittal.com/europe/products/HYTSS/BH/EN.
Extended choice of materials and parameters used
by a key car manufacturer (BMW)

Extended choice of materials and parameters used
by a key car manufacturer (BMW)

Main criteria and ratings for realistic
selection of automotive body materials

High strength steel grades commonly
available in Europe

Automotive aluminum alloys in current use

Common automotive magnesium alloys
UTS : Ultimate Tensile Strength

Aluminum as an auto body material
Advantages and disadvantages of aluminum as an auto body
material:
Advantages:
• Low density
• Corrosion resistance
• Strong supply base
• Recyclability
Disadvantages:
• High and fluctuating cost
• Poorer formability than steel
• Less readily welded than steel

Honda NSX - Aluminum
Aluminum alloys used
for Honda NSX body
panels.

Tailored Blank
Tailored blanks are semi-finished parts, which are
typically made from sheets with different alloys,
thicknesses, coatings or material properties. After
joining these will be subjected to deep drawing or
stamping.
Tailored blanks were developed by

ThyssenKrupp, to make sheets that were wider
than those made on available rolling mills of the
time. These days, tailored blanks are used to
make e.g. door panels which are thick near the
hinges and thin near the lock to withstand
different types of loads or corrosion attacks. They
are lighter and often cheaper than conventional
sheets. Tailored Blanks are typically made from
steel. Aluminum and dissimilar material tailored
blanks are also available but less common.
Reference: wikipedia.org
Utilization of different material forms within
future body structures

Properties of plastics
Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

A typical engine manifold manufactured from
Bayer glass filled nylon 6, for Mercedes Benz
Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

Extrusion vs. Pressed Parts
Sill sections produced from pressed parts compared with extruded

sections

Chassis Design Example



Mercedes SL (R 231)
Ferrari 360 Modena materials

Extent of use of composites — exploded
assembly of car

Monocoque assembly

Internal structure of Aston Martin Vanquish showing
carbon fiber composite and extrusion construction

Side view of Aston Martin Vanquish

Progressive improvement in torsional
stiffness shown for successive BMW model
generations.

Relationship of body-in-white weight
to curb weight

Increasing proportion of high strength steel
used in BMW body structures.

Recycling

Recycling

Future ?


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VEHICLE DESIGN

Atabay - Istanbul Technical University 1

Automotive Materials and Production

Atabay - Istanbul Technical University 2

Atabay - Istanbul Technical University 3

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Atabay - Istanbul Technical University 10

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

HSS : High strength steel, more commonly referred to as high-strength low-

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

The composition and processing of these

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

UTS : Ultimate Tensile Strength

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Atabay - Istanbul Technical University 22

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Tailored blanks were developed by

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

Sill sections produced from pressed parts compared with extruded

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Crolla, D.A., Automotive Engineering, Elsevier, 2009.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

Reference: Davies, G., Materials for Automobile Bodies, Elsevier, 2003.

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