5 Series BIW
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Transcript of 5 Series BIW
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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