amap aluminium application in lightweight electric car design
TRANSCRIPT
© fka 2015· All rights reserved 2015/05/21 Slide No. 1 #150 · 15ho0019.pptx
Aachen, 21 May 2015
Dipl.-Ing. Björn Hören MBA
Forschungsgesellschaft Kraftfahrwesen mbH Aachen RWTH Aachen University
Prof. Dr. Hirsch
Hydro Aluminium Rolled Products GmbH
Aluminium Application in Lightweight Electric Car Design
AMAP
© fka 2015· All rights reserved 2015/05/21 Slide No. 2 #150 · 15ho0019.pptx
Introduction of ika / fka Full vehicle competence
CEO
Dr.-Ing. Markus Bröckerhoff
Director
Univ.-Prof. Dr.-Ing. Lutz Eckstein
Full Vehicle
Acoustics
Thermal Management
Vehicle Concepts
Strategy and Consulting
Driver Experience and
Performance
Drive
r A
ssis
tan
ce
Ele
ctr
ics/
Ele
ctr
on
ics
Body
Drive
tra
in
Ch
assis
Founded in 1902 (ika) and 1981 (fka)
ika has approx. 350 employees:
90 engineers, 56 workers, technicians and apprentices,
about 200 student workers
Together with co-operation partner fka access to a total
staff of approx. 450 employees
References:
Automotive customers from Europe, USA and Asia
OEM and suppliers
Public funded research
© fka 2015· All rights reserved 2015/05/21 Slide No. 3 #150 · 15ho0019.pptx
Agenda
Motivation of Lightweight Design
Material Characteristics
Multi-Material Concept Light-eBody
Hydro's Full Aluminium Concept
Outlook and Conclusion
© fka 2015· All rights reserved 2015/05/21 Slide No. 4 #150 · 15ho0019.pptx
Motivation of Lightweight Design The Road Transport System is Facing a Multitude of Challenges
Demographic
change
Urbanisation
Emissions
Congestion
Crime
Climate change
Accidents
Individualisation
of mobility needs
Public debt
Rising costs of energy and fuel
Limited
resources
Connectivity
© fka 2015· All rights reserved 2015/05/21 Slide No. 5 #150 · 15ho0019.pptx
Motivation of Lightweight Design Saving Potentials and Weight Helix
Reduction of fuel consumption/CO2 emission
Reduction per 100 kg weight saving (in NEDC):
- 0.15 l/100 km/ 3.75 g CO2/km (primary effects)
- 0.30 l/100 km (secondary effects)
CO2 emission targets correspond to
- 5.6 g / 100 km (Petrol)
- 4.9 g / 100 km (Diesel)
Source: Volkswagen
600
800
1000
1200
1400
1600
1800
1970 1980 1990 2000 2010
Gross vehicle weight development
(mV)
Golf I
Golf II
Golf III Golf IV
Golf
V Golf VI
kg
Golf VII
„Weight helix“ Energy
storage Chassis
Body and
interior
-kg
Drivetrain
© fka 2015· All rights reserved 2015/05/21 Slide No. 6 #150 · 15ho0019.pptx
Motivation of Lightweight Design CO2-Regulation and Oil Price
Limited resources
Rising energy cost
CO2-emission Regulation
+ 76 %
Fleet emissions 2009:
VW: 153 g/km
BMW: 158 g/km
Audi: 163 g/km
Daimler: 179 g/km
Super
1998
0,80 €/l
Super
2015
1,41 €/l
Fleet emissions 2013:
VW: 134 g/km
BMW: 139 g/km
Audi: 140 g/km
Daimler: 149 g/km
2020
95 g CO2/km
Europe
2020
101 g CO2/km
USA
2020
5 l/100 km
China
© fka 2015· All rights reserved 2015/05/21 Slide No. 7 #150 · 15ho0019.pptx
Agenda
Motivation of Lightweight Design
Material Characteristics
Multi-Material Concept Light-eBody
Hydro's Full Aluminium Concept
Outlook and Conclusion
© fka 2015· All rights reserved 2015/05/21 Slide No. 8 #150 · 15ho0019.pptx
0
500
1000
1500
0 20 40 60 80
Material Characteristics Limits of Steel Lightweight Design
The right material at the right place:
Choice of material depending on component requirements and material properties
Sheet thickness reduction limited e.g. due to stiffness and NVH
Global body stiffness declines because of equal Young’s modulus
High strength steel not suitable for all components because of lower maximum elongation
Specific material properties
Spec. stiffness [GPa/(g/cm³)]
Spec. str
ength
[MP
a/(
g/c
m³)
] Steel/Al/Mg
GFRP fabric
GFRP UD
CFRP fabric
CFRP UD
NVH, stiffness, availability
Sheet / w
all
thic
kness Limited lightweight potential
Lightweight development
© fka 2015· All rights reserved 2015/05/21 Slide No. 9 #150 · 15ho0019.pptx
Material Characteristics Lightweight Potential and CO2-Emissions
Lower vehicle weight leads to less energy consumption during usage
Lightweight materials show higher CO2-emissions and cost in production and recycling
Source: Volkswagen AG
0
10
20
30
40
0
25
50
75
100
Ste
el
(co
nve
nt.
)
Ste
el (h
ot
form
ed
)
Alu
min
ium
Ma
gn
esiu
m
CF
RP
Ma
ss [%
]
Co
st [%
]
-10
to
-2
5 %
-40
%
-50
%
-75
%
CO
2-E
imis
sio
n R
aw
Ma
teri
al [C
O2-e
q./
kg
]
© fka 2015· All rights reserved 2015/05/21 Slide No. 10 #150 · 15ho0019.pptx
Cost Breakdown for high-volume Car
30%
10%
7%
53% cost
research
material tooling production repair
A: minimum cost
B: cost neutrality
C: economic optimum
for the manufacturer weight
basis A B
C
Material cost
Production cost
R&D costs
Other costs
development
Material Characteristics Cost Versus Weight
Lightweight design
© fka 2015· All rights reserved 2015/05/21 Slide No. 11 #150 · 15ho0019.pptx
Material Characteristics Compensation of Lightweight Cost
Compensation of the higher weight of alternative drivetrains
New economic aspects for lightweight design:
Lightweight costs for alternative drivetrains are (partly) compensable
Hybrid drive
Electric drive Sources: BMW Group, Volkswagen AG 0
2
4
6
8
10
12
14
16
18
20
1000 900 800 700 600 500 400 300 200
Ein
sp
aru
ng
pro
kg
Gew
ich
tsre
d. [€]
Spezifische Batteriesystemkosten [€/kg]
Energiedichte
100 Wh/kg
200 Wh/kg
300 Wh/kg
Specific battery system costs [€/kWh]
Drive range NEDC: 200km
150 km
100 km
50 km
Batt
ery
cost re
duction p
er
kg w
eig
ht
reduction [€]
Energy density
Source: ika
© fka 2015· All rights reserved 2015/05/21 Slide No. 12 #150 · 15ho0019.pptx
Material Characteristics Aluminium Trend in Automotive Industry
Full aluminium versions also for high volume production
Potential design approaches: space frame and self-supporting uniform
Time
From smaller to higher volume production
From hybrid design to full aluminium design
Steel
High strength steel
Ultra high strength steel
Aluminium
Passat Golf study Full Aluminium Body
© fka 2015· All rights reserved 2015/05/21 Slide No. 13 #150 · 15ho0019.pptx
Agenda
Motivation of Lightweight Design
Material Characteristics
Multi-Material Concept Light-eBody
Hydro's Full Aluminium Concept
Outlook and Conclusion
© fka 2015· All rights reserved 2015/05/21 Slide No. 14 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Project Targets
Development of an innovative multi-material lightweight body-in-white (BIW)
Suitable for an electric vehicle in mass production Cost competitive lightweight design
Intensive use of profiles for the vehicle load bearing structure
Lightweight panels made from low density materials
Integration of the battery in the vehicle structure as load bearing element
Development of new material concepts and production processes for multi-material design
Further development of simulation methods and joining technologies
All technologies and lightweight cost have to be suitable for mass production (1.000 /d)
Life Cycle Analysis to evaluate the environmental impact of the concept
© fka 2015· All rights reserved 2015/05/21 Slide No. 15 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Project Structure
WP3
Development of
Simulation Methods
(ika, VW, TKSE, L+W,
Dow, Hydro, LWF,
Altair, ISF, LBF)
WP1
Structural/Body
Design
(ika, Ford, TKSE,
L+W, Hydro,
Röchling, Böllhoff,
ISF, LBF)
WP2
Materials, Joining/
Production Processes
(ika, VW, TKSE, L+W,
Dow, Hydro, Röchling,
Böllhoff, LWF, ISF, LBF)
Light-eBody
Project Organisation: ika
WP4.1 Acoustics
WP4.2 Structural Integration of the Battery
WP4.3 Life Cycle Assessment
Cro
ss
Cu
ttin
g
Iss
ue
s
© fka 2015· All rights reserved 2015/05/21 Slide No. 16 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Use Case and Concepts
Use case: urban/commute
Seats: 2+3
Range: > 150 km (NEDC)
vmax: 150 km/h
Production: large volume (1,000/d)
Segment: C
Conservative Approach:
Small changes
Shell design
Multi-Material Approach
Purpose design
Profile intensive design
Conservative Concept Light-eBody Project
© fka 2015· All rights reserved 2015/05/21 Slide No. 17 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Conservative Concept
Conversion of the conventionally powered Golf V into an electric vehicle
Changes and reinforcements are necessary for
Protection of the battery cells
Adaption for new crash load cases
Define project target values e.g. reference weight and intrusion limits
Additional weight of reinforcements, changes and the battery structure: 35 kg
Drivetrain Additional structure / Reinforcements
© fka 2015· All rights reserved 2015/05/21 Slide No. 18 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Drivetrain of the Light-eBody and the Full Aluminium Concept
Battery system
Engine with
power electronics
© fka 2015· All rights reserved 2015/05/21 Slide No. 19 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Load Pathes of the Light-eBody and the Full Aluminium Concept
Legend
Body Structure
Battery Structure
Load pathes
© fka 2015· All rights reserved 2015/05/21 Slide No. 20 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Accra Technology
Profile based structural components in the area of the passenger cell
Based on simple modes of action
Combination of Hotforming, Hydroforming and Hardening
Material grades comparable to press hardening components
Complex three dimensional formed part geometries with load optimised sections
High repeat accuracy by high cooling rates
Inside pressure Quenching Austenitising Molding
© fka 2015· All rights reserved 2015/05/21 Slide No. 21 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody T³ Profile Technology
Flangeless profiles for optimal usage of the section space
Thickness and weight reduction
Design benefits from part integration
Crash performance benefits from reduced pre-strain
Wide range of different cross sections is possible
All steel grades, Tailored Blanks possible
Indirect press hardening
Manufacturing on standard press line (high volume)
welding press line
U- form O- form Blanking
© fka 2015· All rights reserved 2015/05/21 Slide No. 22 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Design
© fka 2015· All rights reserved 2015/05/21 Slide No. 23 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Body-in-White
© fka 2015· All rights reserved 2015/05/21 Slide No. 24 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Profile Technologies
Steel Profiles
Accra
T³
Hydroforming
Rollforming
Aluminium Profiles
Tailor Rolled Tube
Extrusion
Lightweight Panels
Aluminium Sheet
Stratura
© fka 2015· All rights reserved 2015/05/21 Slide No. 25 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Aluminium Sheet Applications
Steel Profiles
Accra
T³
Hydroforming
Rollforming
Aluminium Profiles
Tailor Rolled Tube
Extrusion
Lightweight Panels
Aluminium Sheet
Stratura
© fka 2015· All rights reserved 2015/05/21 Slide No. 26 #150 · 15ho0019.pptx
Definition of requirements
and identification of
potential technologies
Experimental analysis
and optimization of
suitable joining
technologies
Development of models
for representation
of joint properties in
car body FE-model
Joining technologies used for the Light-eBody concept:
(Indirect) resistance spot welding, GMA welding, laser beam welding, resistance element welding, self-pierce
riveting, RIVTAC® and more
Source: LWF
Source: FORD
Multi-Material Concept Light-eBody Joining
© fka 2015· All rights reserved 2015/05/21 Slide No. 27 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody FEM Analysis Euro NCAP ODB
© fka 2015· All rights reserved 2015/05/21 Slide No. 28 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody FEM Analysis
Frontal Offset Impact Target Evaluation
Firewall intrusion < 125 mm
A-Pillar displacement < 20 mm
Intrusion into battery compartment < 15 mm
Deceleration pulse max. 50 g
Side Impact - Pole Target Evaluation
Sidewall intrusion < 340 mm
Intrusion into battery compartment < 15 mm
Deceleration pulse max. 30 g
Euro NCAP
Rear Impact Target Evaluation
Max. intrusion < 465 mm
Intrusion into battery compartment < 15 mm
FMVSS
© fka 2015· All rights reserved 2015/05/21 Slide No. 29 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody FEM Analysis
Side Impact Target Evaluation
Sidewall intrusion < 320 mm
Intrusion into battery compartment < 15 mm
Deceleration pulse max. 35 g
IIHS
Static Torsion Target Evaluation
Torsional stiffness ≥ 25500 Nm/°
Eigenfrequencies Target Evaluation
Torsion global ≥ 45 Hz
Lateral bending ≥ 48 Hz
Bending Torsion Static Analysis
Eigenfrequencies
© fka 2015· All rights reserved 2015/05/21 Slide No. 30 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Weight Reduction
Conservative concept
Body-In-White + Battery structure 314 kg
Light-eBody
Body-In-White + Battery structure 256 kg
Secondary weight reduction by Stratura ca. 10 kg
Weight reduction 58 kg + 10 kg = 68 kg
Lightweight cost (€/kg) are suitable for mass production
© fka 2015· All rights reserved 2015/05/21 Slide No. 31 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Demonstrators
Stratura panel, Accra and T³ profiles were build up as prototypes and included into a demonstrator
© fka 2015· All rights reserved 2015/05/21 Slide No. 32 #150 · 15ho0019.pptx
Agenda
Motivation of Lightweight Design
Material Characteristics
Multi-Material Concept Light-eBody
Hydro's Full Aluminium Concept
Outlook and Conclusion
© fka 2015· All rights reserved 2015/05/21 Slide No. 33 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Weight Reduction
© fka 2015· All rights reserved 2015/05/21 Slide No. 34 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Profile Technologies
Extrusions
Bended extrusions
Tailor Rolled Tube
Hydroforming
Cast nodes
© fka 2015· All rights reserved 2015/05/21 Slide No. 35 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Material Validation and Choice of material models
• Test data example 606035-T6 and C24-X1-T7
anisotropic material model (*MAT_36) for 606035-T6 and C20-Y1-T6
isotropic model (*MAT_24) for C24-X1-T6/7 and C28-C2-T6
200
240
280
320
360
400
0 0,02 0,04 0,06 0,08 0,1 0,12 0,14 0,16
Tru
e S
tre
ss M
pa
True Strain %
606035-T6-0°
606035-T6-45°
606035-T6-90°
200
240
280
320
360
400
0 0,05 0,1 0,15
Tru
e S
tre
ss
[M
pa
]
True Strain
C24-X1-T7-0 C24-X1-T7-45 C24-X1-T7-90
200
240
280
320
360
400
0 0,05 0,1 0,15
Tru
e S
tre
ss
[M
pa
]
True Strain
606035-T6-0 606035-T6-45 606035-T6-90
© fka 2015· All rights reserved 2015/05/21 Slide No. 36 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Simulation in Comparison to the Test data
Comparison with test videos of 606035 (anisotropic) and C24 (isotropic)
© fka 2015· All rights reserved 2015/05/21 Slide No. 37 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Forming Optimised AA5182 for Inner Applications
Established alloy type: AA5182
Door inner panels with requirements on:
Strength
Stiffness
Good corrosion resistance (IGC)
High formabilty to allow for:
=> integrated window frame
=> large depth of draw
High formability, good corrosion resistance
(examples presented by BMW at ACI Insight Ed. 2010 ; Castle Bromwich)
© fka 2015· All rights reserved 2015/05/21 Slide No. 38 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept New Alloys for Outer Skin Parts, e.g. the Sidewall
Hydro‘s HA6016-U is a conventional, AA6016-based alloy, for applications:
Requiring high formability
Combined with typical mechanical properties
High demands on surface appearance (outer skin quality)
Hydro‘s HA6016-X is a AA6016 multilayer alloy
Step change with regard to formability of 6xxx alloys
High demands on surface appearance (outer skin quality)
1-piece side panel Bolloré Bluecar.
HA 6016-U
functional Al-layer
functional Al-layer
© fka 2015· All rights reserved 2015/05/21 Slide No. 39 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Euro NCAP – Frontal Impact (ODB)
© fka 2015· All rights reserved 2015/05/21 Slide No. 40 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept IIHS – Side Impact
© fka 2015· All rights reserved 2015/05/21 Slide No. 41 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Euro NCAP – Pole Impact
© fka 2015· All rights reserved 2015/05/21 Slide No. 42 #150 · 15ho0019.pptx
Hydro's Full Aluminium Concept Overview Results
EuroNCAP
FMVSS
Pole Side Impact Target Evaluation
Sidewall intrusion < 340 mm
Intrusion into battery compartment < 15 mm
Deceleration pulse max. 25 g
ODB Front Crash Target Evaluation
Firewall intrusion < 125 mm
Intrusion into battery compartment < 15 mm
Deceleration pulse max. 50 g
Rear Impact Target Evaluation
Max. Intrusion < 465 mm
Intrusion into battery compartment < 15 mm
© fka 2015· All rights reserved 2015/05/21 Slide No. 43 #150 · 15ho0019.pptx
IIHS
Stiffness
Stiffness Target Evaluation
Torsional stiffness > 25.500 Nm/°
Eigenfrequencies Target Evaluation
1st Torsion > 45 Hz
1st Bending > 48 Hz
Hydro's Full Aluminium Concept Overview Results
Side Impact Target Evaluation
Sidewall intrusion < 320 mm
Intrusion into battery compartment < 15 mm
Deceleration pulse max. 25 g
© fka 2015· All rights reserved 2015/05/21 Slide No. 44 #150 · 15ho0019.pptx
Multi-Material Concept Light-eBody Weight Reduction
Conservative concept
Body-In-White + Battery structure 314 kg
Light-eBody
Body-In-White + Battery structure 199 kg
Weight reduction 115 kg
Assumed lightweight cost (€/kg) are higher as for the Light-eBody concept
(Weight reduction of the Light-eBody Concept 68 kg)
© fka 2015· All rights reserved 2015/05/21 Slide No. 45 #150 · 15ho0019.pptx
Agenda
Motivation of Lightweight Design
Material Characteristics
Multi-Material Concept Light-eBody
Hydro's Full Aluminium Concept
Outlook and Conclusion
© fka 2015· All rights reserved 2015/05/21 Slide No. 46 #150 · 15ho0019.pptx
Outlook and Conclusion
Lightweight design lowers the energy demand of electric vehicles
Integration of the battery structure as load bearing exploits lightweight potential
Light-eBody (Multi-Material Design)
New production processes and joining technologies were analysed and developed for mass production
suitability
CAE methods for the simulation of the joining of the material combination were developed
Full Aluminium Concept (Hydro)
Improving design for suitable light-weight-car design concepts Hydro Aluminium R&D together with fka
helps to develop new economic and efficient electric car concepts
High lightweight potential is achieved with Aluminium at reasonable cost level, suitability for large scale
production
Improving specific properties of Aluminium alloys (5xxx, 6xxx, …)
Aluminium shows higher lightweight cost but also a higher lightweight potential
Suitability of the lightweight concepts depends on the affordable lightweight cost
© fka 2015· All rights reserved 2015/05/21 Slide No. 47 #150 · 15ho0019.pptx
Phone
Fax
Internet www.fka.de
fka Forschungsgesellschaft Kraftfahrwesen mbH Aachen
Steinbachstr. 7
52074 Aachen
Germany
Contact
Dipl.-Ing. Björn Hören MBA
+49 241 80 25609
+49 241 8861 110