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BMW

Group

Technological Innovations in Body in White Manufacturing of the BMW X6

Innovations in Body in White Manufacturing of the BMW X6 Markus Pfestorf BMW Group Duane Copeland

Markus Pfestorf BMW Group Duane Copeland BMW MC

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

BMW

Group

Content

• Body in White Requirements for EfficientDynamics

• Body in White Materials

• Ultra High Strength Steel Grades

• Joining Technologies

• Conclusion

Materials • Ultra High Strength Steel Grades • Joining Technologies • Conclusion w w w .
Materials • Ultra High Strength Steel Grades • Joining Technologies • Conclusion w w w .

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Materials • Ultra High Strength Steel Grades • Joining Technologies • Conclusion w w w .

BMW

Group

Body in White Requirements Efficient Dynamics

Body In White Weight Load Distribution and Axle Power Train EfficientDynamics Axle and Kinematics Aerodynamics
Body
In
White
Weight
Load
Distribution
and Axle
Power Train
EfficientDynamics
Axle and
Kinematics
Aerodynamics
and Axle Power Train EfficientDynamics Axle and Kinematics Aerodynamics w w w . a u t

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and Axle Power Train EfficientDynamics Axle and Kinematics Aerodynamics w w w . a u t

BMW

Group

Body in White Requirements Cost Efficient Light Weight Design

in White Requirements Cost Efficient Light Weight Design Specific Panels Shared Panels - Torsional Stiffness of

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

Cost Efficient Engineering using existing Panels with a maximum Design Differentiation w w w . a

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Cost Efficient Engineering using existing Panels with a maximum Design Differentiation w w w . a

BMW

Group

Body in White Materials Yield Strength

180 MPa

200-220 MPa, 4 %

15% 260 MPa 7% Deep Drawn Steel 14% 300 MPa 18% Others, 4% 6xxx Aluminum,
15%
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%
Others, 4% 6xxx Aluminum, 2% 950 MPa, 3% 380-420 MPa, 25% 680 MPa, 5% 550 MPa,

550 MPa, 3%

Others, 4% 6xxx Aluminum, 2% 950 MPa, 3% 380-420 MPa, 25% 680 MPa, 5% 550 MPa,
Others, 4% 6xxx Aluminum, 2% 950 MPa, 3% 380-420 MPa, 25% 680 MPa, 5% 550 MPa,

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Others, 4% 6xxx Aluminum, 2% 950 MPa, 3% 380-420 MPa, 25% 680 MPa, 5% 550 MPa,

BMW

Group

Body-In-White Materials Average Minimum Yield Strength

500 475 MPa 400 350 ? Current X5 X6 300 3´Series Sedan 3´Series Sports W.
500
475
MPa
400
350
?
Current X5
X6
300
3´Series Sedan
3´Series Sports W.
3´Series Coupé
1´Series
250
3´Series
5´Series
7´Series
Sports Wagon
6´Series Convertible
6´Series Coupé
3´Series
5´Series
5´Series
Z4´Coupé
Sedan
Z4
200
Sports Wagon
3´Series
Previous X5
Compact
3´Series
7´Series
5´Series
Coupé
150
Sports Wagon
3´Series
Convertible
1994
1996
1998
2000
2002
2004
2006
20082008
2010
Average min. Yield Strength R p0,2
2002 2004 2006 20082008 2010 Average min. Yield Strength R p0,2 Start of Production w w

Start of Production

2002 2004 2006 20082008 2010 Average min. Yield Strength R p0,2 Start of Production w w

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2002 2004 2006 20082008 2010 Average min. Yield Strength R p0,2 Start of Production w w

BMW

Group

Body-In-White Materials Average Thickness

1,7 mm 3´Series Convertible 1,5 Z4 1,4 Without Advanced High Strength Steel 6´Series Convertible 1,3
1,7
mm
3´Series Convertible
1,5
Z4
1,4
Without Advanced
High Strength Steel
6´Series Convertible
1,3
Current X5
6´Series Coupé
X6
1,2
3´Series Sports Wagon
Previous X5
7´Series
1,1
5´Series Sports Wagon
5´Series
1´Series
1,0
7´Series
0,9
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
Average Thickness
1996 1998 2000 2002 2004 2006 2008 2010 Average Thickness Start of Production w w w

Start of Production

1996 1998 2000 2002 2004 2006 2008 2010 Average Thickness Start of Production w w w

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1996 1998 2000 2002 2004 2006 2008 2010 Average Thickness Start of Production w w w

BMW

Group

BMW Group UHSS – Hot Stamped 22MnB5 Side Crash Thickness (t) t = 1.2 mm t

UHSS – Hot Stamped 22MnB5 Side Crash

Thickness (t)

t

= 1.2 mm

t

= 2.2 mm

t

= 1.4 mm

t

= 1.2 mm

1.2 mm t = 2.2 mm t = 1.4 mm t = 1.2 mm Weight Savings:

Weight Savings: 2 kg/side

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

Mechanical Values:

Yield Strength R p0,2 :

Tensile Strength R m : > 1300 MPa

> 950 MPa

Strength R p 0 , 2 : Tensile Strength R m : > 1300 MPa >

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Strength R p 0 , 2 : Tensile Strength R m : > 1300 MPa >

BMW

Group

UHSS – CP800 Rear Crash

BMW G r o u p UHSS – CP800 Rear Crash (Complete Longitudinal rear member including
BMW G r o u p UHSS – CP800 Rear Crash (Complete Longitudinal rear member including

(Complete Longitudinal rear member including other steel grades)

Weight Savings for the Longitudinal Rear Member:

4,4 kg

Mechanical Values:

Yield Strength R p0,2 :

Tensile Strength R m : 800 - 980 MPa

680 - 830 MPa

Elongation A 80 :

> 10%

Tensile Strength R m : 800 - 980 MPa 680 - 830 MPa Elongation A 8

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Tensile Strength R m : 800 - 980 MPa 680 - 830 MPa Elongation A 8

BMW

Group

UHSS – CP800 Rear Crash of a Prototype

BMW Group UHSS – CP800 Rear Crash of a Prototype w w w . a u
BMW Group UHSS – CP800 Rear Crash of a Prototype w w w . a u

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BMW Group UHSS – CP800 Rear Crash of a Prototype w w w . a u

Deformation Force

BMW

Group

UHSS – CP800 Rear Crash

 

Mech. Properties (as delivered)

Mech. Properties (180°C, 60 min.)

Yield Strength R p0,2

692

MPa

796

MPa

Tensile Strength R m

901

MPa

923

MPa

Elong. after Fracture A 80

11,4

10,8

Thickness

0,99

0,99

± 118 mm

± 88 mm
± 88 mm

200

kN

120

80

40

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

Deformation Time

155,84 kN (without Bake Hardening Response) Deformation Time Tested profile Specimen after Drop Test w w

Tested profile

Bake Hardening Response) Deformation Time Tested profile Specimen after Drop Test w w w . a

Specimen after Drop Test

Bake Hardening Response) Deformation Time Tested profile Specimen after Drop Test w w w . a

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Bake Hardening Response) Deformation Time Tested profile Specimen after Drop Test w w w . a

BMW

Group

UHSS – CP800 X6 Part Application

BMW Group UHSS – CP800 X6 Part Application Thickness of all Parts: 1,5 mm w w
BMW Group UHSS – CP800 X6 Part Application Thickness of all Parts: 1,5 mm w w

Thickness of all Parts: 1,5 mm

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BMW Group UHSS – CP800 X6 Part Application Thickness of all Parts: 1,5 mm w w

BMW

Group

UHSS – CP800 Tool Realization Guidelines

a b
a
b

Phase 1

Phase 2

c
c

d

d
d

Phase 3

Tool Realization Guidelines a b Phase 1 Phase 2 c d Phase 3 a Tool Change
Tool Realization Guidelines a b Phase 1 Phase 2 c d Phase 3 a Tool Change
a
a

Tool Change Content :

a) Optimize the release of flange form

b) Optimize the draw of the embossments

c) Increase the radii if necessary

d) Optimize the trim

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

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

BMW

Group

UHSS – CP800 Clamping in Body in White

BMW Group UHSS – CP800 Clamping in Body in White Secure the part fastening assembly process
BMW Group UHSS – CP800 Clamping in Body in White Secure the part fastening assembly process

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.

Optimization of the Clamping Technology. • Higher Measurement Stability in the BIW. w w w .

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Optimization of the Clamping Technology. • Higher Measurement Stability in the BIW. w w w .

BMW

Group

Joining Technologies Materials and Joining Technologies

Spot Weld
Spot Weld

Adhesive Bonding

Main Joining Technologies:

• Resistant Spot Welding (6643 Spot Welds)

• Adhesive Bonding (116999 mm)

Other Joining Technologies:

• Self Pierce Riveting (82)

• Clinching (53)

• Mig Welding and Brazing (8053 mm)

• Capacitance Discharge Welding

Clinching (53) • Mig Welding and Brazing (8053 mm) • Capacitance Discharge Welding w w w

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Clinching (53) • Mig Welding and Brazing (8053 mm) • Capacitance Discharge Welding w w w

BMW

Group

Joining Technologies Benefit of Structural Adhesives

Applied Adhesives
Applied Adhesives
Benefit of Structural Adhesives Applied Adhesives Local Static Transversal Stiffness of the Upper Control Arm

Local Static Transversal Stiffness of the Upper Control Arm

Local Static Stiffness Upper Control Arm

+ 12%

Static Torsional Stiffness

+ 2%

Dynamic Stiffness

+ 0.1Hz

to

+ 0.3Hz

Stiffness + 2% Dynamic Stiffness + 0.1Hz to + 0.3Hz Benefit on Stiffness with Adhesive without
Stiffness + 2% Dynamic Stiffness + 0.1Hz to + 0.3Hz Benefit on Stiffness with Adhesive without

Benefit on Stiffness

2% Dynamic Stiffness + 0.1Hz to + 0.3Hz Benefit on Stiffness with Adhesive without Adhesive Difference

with Adhesive without Adhesive

Difference of Displacements of the Spring Support with and without Adhesive Application

of Displacements of the Spring Support with and without Adhesive Application w w w . a

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of Displacements of the Spring Support with and without Adhesive Application w w w . a

BMW

Group

Joining Technologies Aluminum Casted Front Shock Tower

Supplier

Aluminum Casted Front Shock Tower S u p p l i e r Body In White

Body In White

Front Shock Tower S u p p l i e r Body In White P a

Paint Shop

p p l i e r Body In White P a i n t S h

- High Pressure Vaccum Casting

- Heat Treated

- Machined

- Cataphoretic Painting

- Bonding (ca. 5.4 m)

- Self Pierce Rivets (82 times)

Painting - Bonding (ca. 5.4 m) - Self Pierce Rivets (82 times) w w w .
Painting - Bonding (ca. 5.4 m) - Self Pierce Rivets (82 times) w w w .

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- PVC Sealant

Painting - Bonding (ca. 5.4 m) - Self Pierce Rivets (82 times) w w w .

BMW

Group

Ø 52 mm Ø 90 mm
Ø 52 mm
Ø 90 mm

Joining Technologies Capacitance Discharge Welder

Ø 90 mm Joining Technologies Capacitance Discharge Welder Cold Forged part Material: C15E2C Advantages: - More
Ø 90 mm Joining Technologies Capacitance Discharge Welder Cold Forged part Material: C15E2C Advantages: - More

Cold Forged part Material: C15E2C

Discharge Welder Cold Forged part Material: C15E2C Advantages: - More economical Process - Less Weld Splatter

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.

in Parts during the welding Process - No Process induced Material Structure Change. w w w

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in Parts during the welding Process - No Process induced Material Structure Change. w w w

BMW

Group

Joining Technologies Capacitance Discharge Welder

2 1 Distance (mm) Force (kN)
2
1
Distance (mm)
Force (kN)
Capacitance Discharge Welder 2 1 Distance (mm) Force (kN) 1,0 mm Force vs. Distance Relationships: 1
1,0 mm

1,0 mm

Discharge Welder 2 1 Distance (mm) Force (kN) 1,0 mm Force vs. Distance Relationships: 1 Outer

Force vs. Distance Relationships:

1 Outer projection

2 Inner projection

Internal Weld Seam Evaluation:

- Small Fusion Zone

- Small heat induced Zone

- Continuous Material Connection

200 µm

- Small Fusion Zone - Small heat induced Zone - Continuous Material Connection 200 µm w

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- Small Fusion Zone - Small heat induced Zone - Continuous Material Connection 200 µm w

BMW

Group

Conclusion

• 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

Discharge Welding for Bushings – High local stiffness – Extreme short Process Time w w w

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Discharge Welding for Bushings – High local stiffness – Extreme short Process Time w w w

BMW

Group

Thank You for Your Attention

BMW Group Thank You for Your Attention w w w . a u t o s
BMW Group Thank You for Your Attention w w w . a u t o s
BMW Group Thank You for Your Attention w w w . a u t o s
BMW Group Thank You for Your Attention w w w . a u t o s
BMW Group Thank You for Your Attention w w w . a u t o s
BMW Group Thank You for Your Attention w w w . a u t o s

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BMW Group Thank You for Your Attention w w w . a u t o s