Transcript
The Body in White of the new The Body in White of the new The Body in White of the new The Body in White of the new
BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.
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BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.BMW 5 Series Gran Turismo.
Duane CopelandDuane CopelandDuane CopelandDuane CopelandBMW AG
Markus PfestorfMarkus PfestorfMarkus PfestorfMarkus PfestorfBMW AG
Contents
I) Introduction
II) Concept of the Car
III) Materials and Manufacturing Technologies
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Introduction
Personal Space- Semi Command Position- Perfect Entry- Rear Leg Room- Sedan-like Separated Trunk- Panoramic Roof
Coupe-Like Exterior- Coupe-Like Silhouette- Frameless Doors- High-Quality Appearance of Exterior - (ex. chrome and high gloss black elements)
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- Panoramic Roof
Modern, Elegant Interior- New Type of High-Quality Interior- Extended Ambient Light- Single Rear Seat Configuration (option)
Functionality- Twin-Trunk Lid- Trunk Volume- Flexible 2nd Seat Row / Trunk Size
Relative Product Dimensions
1678 1456 1555
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BMW X6
BMW 7 series
BMW 5 series Gran Turismo
2933 3070 3070
Technical Components for EficientDynamics
Lower CO2 Emissions
Efficient TwinPower Turbo Engines
Integral-V-MultilinkSuspension
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Runflat Tires
Turbo Engines
Eight Gear Automatic Transmission with Steptronic
Double-WishboneFront Axle
Light Weight Body in White Design
Torsional Stiffness and Lightweight CoefficientTo
rsio
na
l stiffn
ess c
T
L
27,5003.0
L
31,500
2.6
15.000
20.000
25.000
30.000
Nm/°
40.000
Lig
htw
eig
ht co
effic
ien
t L
1,5
2,0
2,5
3,0
4,0
3,5cT
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To
rsio
na
l stiffn
ess c
L = mGer
CT x A[ x 10³ ]
Kg
Nm/°x m²
L Lightweight CoefficientmGer. Weight of Body-in-WhitecT Torsional StiffnessA Area (wheel base x track width)
LL
0
5.000
10.000
15.000
Sun RoofClosed Roof
Lig
htw
eig
ht co
effic
ien
t L
0
0,5
1,0
1,5
Increase of Stiffness in the Front and Rear End
High Pressure Cast Aluminum Shock Tower
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Struts Torsion Frame
Steel
AluminumAluminum Struts
Passive Safety
Passive safetyActive safety Crash
Correction
Driving
Warning
Crash Unavoidable Post Crash
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cT
Stiffness Strength
Load Path of Side Impact
B-Pillar
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Impact
Hot Stamped Components
USNCAP Barrier
Barrier Weight = 1368 kg
•Passenger Values OK
•Doors Remain Closed
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Barrier Weight = 1368 kg
8 Cylinder 4-Wheel Drive
(incl. simulated luggage)
Load = 2555 kg
Materials
Aluminium
Steel
DC04
DX54D
DX56D
HC180BD, HC180YD
HC220BD, HC220YD
HC260BD, HC260LAD, HC260X(D)
HC300BD, HC300LAD, HC300X
HC340LAD, HC340X(D)
HC380LAD
HC400T
HC420LAD, HC450X
HC600C, HD680C
HC700X
HC1000W (+TE), HC1000WD+ZF
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Others
Other metallic materials
Aluminium
AlMg3,5Mn
AlMg4,5Mn0,4
AlMg1/AlMg5,7/AlMg1
AlMg0,4Si1,2
AlSi0,6Mg0,5
AlSi10MgMnFe
AlMgSi
Materials of the Structure
180 MPA7%
200 – 220 MPa9%
260 MPa10%
AlSi Aluminum
Others5%
300 - 340 MPa21%
Deep Drawn Steel19%
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380 - 450 MPa14%
600 - 700 MPa1%
1000 MPa12%
AlSi Aluminum2%
21%
Weight Savings Compared to Conventional Steel Grades
Hot Stamped Parts: -20,7 kg
Tail Gate: -13,2 kg
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Shock Tower: -4,0 kg
Hood: -7 kg
Doors: -16 kg
Tail Gate: -13,2 kg
Total weight savings due to lightweight material design: 60,9 kg
Hot Stamped Parts
B-Pillar ReinforcementMaterial: HC1000WD+ZFThickness 1,80
B-Pillar Reinforcement InnerMaterial: HC1000WThickness 1,60
A-Pillar ReinforcementMaterial: HC1000WThickness 1,60
Longitudinal Side Member InnerMaterial: HC1000WD+ZFThickness 1,50
Hinge Carrier ReinforcementMaterial: HC1000WD+ZFThickness 1,60
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Uncoated Material
Zinc Coated Material
Tunnel ReinforcementMaterial: HC1000W+TEThickness: 1,50
Longituidinal Side Member OuterMaterial: HC1000WD+ZFThickness 1,00
Press Hardening Process for Zinc Coated Boron Steel
Hot dipped galvanized coil
Cold forming Austenizing + press hardening
Cleaning(optional)
Oiling (optional)
Annealing(optional)
1. Form and Trim in a conventional cold forming process.
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1. Form and Trim in a conventional cold forming process.
2. Heat up the part to Austenitizing Temperature.
3. Pressharden by Quenching in a cooled die.
4. Cleaning of the parts to remove Oxide Layer (optional).
Press Hardening Process for Zinc coated Boron Steel
Film
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Film
Press Hardening Process Window
min. Time for Mechanical Properties (austenitization of the
material)
Process Window max. Time for • Welding• Corrosion Protection• Paint Adhesion• Glue Adhesion(Oxide layer and Fe
Increase of Oxide Layer
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(Oxide layer and Fe
content)
Oxide Layer
Zn Fe Coating
Basic Material
Barrier and Cathodic Protection
B. Region along the Scratch:
• Cathodic Protection
• No Base Material Corrosion
• Corrosion Creep of Paint:
A. Overview Picture:
• Zinc Coated Hot Formed
Steel after 10 weeks of
testing
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100µm
50µm
Conclusion:
• Protection exists even with damaged surface and along cut edges
• Application in wet areas without supplementary support
• Corrosion Creep of Paint:
0,4mm
C. Undamaged Region:
• Barrier and Cathodic Protection Zn Fe Coating
22MnB5
Iron Zinc
Coating Properties – Zinc Distribution
22MnB5
Zn-Fe-
Layer
10µm 10µm
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Conclusion:
• no zinc within the base material
• no Embrittlement of grain boundaries by zinc
Zinc-, Iron- Distribution
22MnB5Zn-Fe Layer
Other Applications of Zinc Coated Boron Steel
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BMW 7 series (SOP 2008) BMW 5 series (SOP 2010)
Application of Dual Phase Steel
w w w . a u t o s t e e l . o r gDachrahmen innen hinten an Serienstand angepasst 14.09.09
Steel Grades
HC260XD
HC300X
HC340X(D)
HC400T
HC450X
HC600C, HD680C
Work Hardening of Dual Phase Steel (HC450X)
Specimen
1
Thinning
min.
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2
Bent Part
Deep Drawn Part
Section 1 Section 2
548 MPa 557 MPa
767 MPa 580 MPa
Measured Yield
Strength
max.
Thank You for Your Attention
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