full aluminium body for pev - lbcg

Full Aluminum Body for PEV

Fei Xiong (Ph.D)

GEELY Auto

About Geely Auto

Why aluminum – Lightweight Technology

Geely PEV Project

PEV Lightweight Target

PEV Lightweight Technology Analysis

Challenges

Contents

Contents


Geely PEV Project



Challenges

Why Aluminium - Lightweight?

~35 kg ~ 13 kg


--- Automotive Lightweight Technology Background

Fuel

GB19578、CAFE、ACEA

Emission

July 1, 2014 – National IV emission standard

Policies

Fuel Economy

Vehicle Dynamics

Customers

Cost

1kg reduction in weight results in $10 saving.

Competitiveness

Lightweight technology – company core competitiveness

Toyota: Target – weight reduction of 10~30% by 2016 in its all small to medium vehicles.. Almost every OEM has its own lightweight target 、、、

OEM Competitiveness


Lightweight Index Trend

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

54.91

4.16

3.26 3.17 3.09 2.962.79 2.79

2.56

3.62 3.59

2.79 2.662.41 2.34 2.22

3.42 3.413.08 3.06

2.47 2.42

1.731.55

1.26

opel_zafiraford_focushyundai_i40_newnissan_leafbmw_1seriesrange_rover_evoqueMercedes-Benz_B-Classmazda_cx-5Audi_A6FORD Fusion/MondeoSKODA RAPIDHONDA CIVICBMW 3 SeriesAUDI A3Cadillac ATSJajur Rang Rover L405 Lexus ISHonda FITALFA ROMEO 4c COUPERenault CaptureRange Rover SportInfiniti Q50Mercedes-Benz S-ClassLamborghini AventadorBMW i3

L=2.56~4.91Average 3.29

L=2.22~3.62Average 2.8

L=1.26~3.42Average 2.48

2011 2012 2013



10

4.99 3.913.35

3.2

3.023.02

2.87 2.7

2.23

1.981.2

0

1

2

3

4

5

6

2014

L=1.2~4.99Average 2.95

--- Automotive Lightweight Technology Background--- Automotive Lightweight Technology Background


11

Lightweight

Technology

Materials Structure Process



6016T6, 1.0mm

B180, 0.7mm

One of the best candidate materials for lightweight

LBK – Material Lightweight IndexAl - better lightweight material in comparison with steel.

（Higher load capacity per unit weight）




Automotive Lightweight demand is pushing wider application of Al alloys.

oon ss noon TT /

Density



Contents


Geely PEV Project



Challenges

AMA platform

XXX model – 5 yrs 200K

Model*Length

mmWidthmm

Heightmm

W/Basemm

Distancekm

MaxSpeedkm/h

A 2742 1566 1566 1868 250 120

Full Alluminium in Geely PEV

Contents


Geely PEV Project



Challenges

第 17 页

Based on the benchmark and competitors 'data ( no less than 5

data) , calculating the average to define C’s average.

L－~10%；A－~20%；C－~40%；U－~30%；

- Products Attribute Leadership Strategy

PEV Lightweight Target (PALS Model)

Benchmark - Smart

Smart curb mass: 943kg，PALS model shows it’s in the uncompetitive rage.

Among of Leaders

Competitive

Uncompetitive

Leadership



A lightweight target of 750kg is set with 5 different body

structure designs.

f(ρ)=𝑀

𝑘∗ 𝐿−𝑤ℎ +𝑤ℎ ∗𝑊∗𝐻



Contents


Geely PEV Project



Challenges

PEV Body Design Analysis

Steel Struct.+Polyme

r Cover（Smart ）

Steel Struct.+Al Cover

（Audi A6）

Full Al Body（Range Rover）

ASF+Al or Polymer Cover）

（Audi A8）

CFRP+PolymerCover

（Lamborghini）

• Design 1：Steel Structure+Polymer Cover

Steel Struct+Compo

sit Closure（Smart ）

W电池重量：参考左图仿真结果，在整备质量（不含电池）一

定的条件下，电池容量与续航里程成正比，推导电池重量与续

航里程也成正比。依此关系，基于Smart（145km续航、电池

178kg），分别计算Smart 80km、150km续航里程的电池重

量为98kg、184kg。

BIW Actual（kg）

Curb Mass (Predic)kg

231 863


－ ﹢＝

W电池 W电池（80km或150km续

航）

Smart电动版整备重量－ ﹢

Steel Struct+Al/Poly

mer Closure

（Audi A6）Design 2 BIW（kg）

CurbMass(Pred)kg

Steel Struct+AlCover

223 855

＝－ ﹢

Al ClosureCurb Mass

（Steel Struct+Composit

Closures）

Polymer Closure－ ﹢

• Design 2：Steel Structure + Al Cover


＝－ ﹢ ﹢

W冲压铝合金骨架W整备重量（钢结构+塑料覆盖件）

W车身（钢结构+塑料覆盖件）

W铝合金覆盖件－ ﹢ ﹢

参考RangeRover

铝合金车身相对钢

制车身减重39%.

187*（1-39%）

=114kg

W全铝车身（参考Range

Rover）

Design 3BIW

（kg）Curb Mass (pred) kg

Al Unibody 150 770

• Design 3：Al Unibody


＝－ ﹢ ﹢

W铝合金骨架整备重量（钢结构+塑料覆盖件）

W白车身（钢结构+塑料覆盖件）

W铝合金或塑料覆盖件－ ﹢ ﹢

Plastic

aluminum

ASF+Al or Polymer Closure

（Benchmark Audi A8）

Design 4BIW

（kg）Curb Mass (Pred)kg

ASF +Al Closure 148 768

ASF + Polymer Closure 156 774

参考audi A8铝

制车身相对钢制

车身减重40%.

187*（1-40%）

=112kg

• Design 4：ASF + Al / Polymer Cover


• CFRP+Polymer Closures

＝－ ﹢ ﹢

W-碳纤维骨架W整备重量（钢结构+塑料覆盖件）

W白车身（钢结构+塑料覆盖件）

W塑料覆盖件－ ﹢ ﹢

Plastic

CFRP+PolymerClosures Design 5

BIW（kg）

Curb Mass (Pred) kg

CFRP+PolymerClosure

124 756

参考兰博基尼慕

拉贡设计，按等

效体积、密度近

似计算，车身骨

架重量80kg。

• Design 4：CFRP Structure+Polymer Cover


PEV Lightweight Technology

No. Body Design MethodPredic. BIW

(kg）Pred. Curb

Mass（kg）

1 Steel Struct.+Polymer Cover 231 863

2 Steel Struct.+Al Cover 223 855

3 Full Al Body 150 770

4ASF+Al Cover 148 768

ASF +Polymer Cover 156 774

5 CFRP+Polymer Cover 124 741

BIW & Curb Mass Evaluation

• Lightweight Design – Mass Analysis

SEV Body Design Analysis


916kg

757kg

670kg

领先间区间

领先区间

竞争性区间

无竞争性区间

Based on the PALS analysis:

① Design 1 and 2 shown uncompetitivenss (Range U)

② Design 3, 4 and 5 shown the curb mass is among A or C.

③ Design 5 shown the curb mass is minimum, among leaders.

PAS Analysis


Full Al Body ASF+Al/Polymer

Annual Production <5000台

Annual Production > 10000

Cost Evaluation – Full Al Unibody

ProposalBIW Weight

（kg）Materials

Percent（Range Rover）

MaterialsWeight（kg）

BIW Cost

#3

114

Al sheet 74% 84.36

7765RMB(~USD1500)

AL casting 15% 17.1

Al extrusion 6% 6.84

AHSS 4% 4.56

UHSS 1% 1.14

36（Aluminum cover）

Al sheet / 36

Full Alluminium Body Cost Assessment

CFRP Design

CFRP+Polymer（Lamborghini

）

Design No.BIW Weight

（kg）Materials

Percent（Murciélago）


BIW Cost

Design 5

80 CFRP 100% 80

RMB$15027(USD$2500)44

（Plastic cover）

Steel /22.17

PP+EPDM-TD20 /12.79

PP-LGF40 /9.35

• BIW Cost Evaluation

CFRP Body Cost Assessment

Design 4.2

ASF + Plastic cover

112

Al sheet 35% 39.2

RMB$4847(~USD$800)

AL casting 35% 39.2


AHSS 4% 4.48

UHSS 4% 4.48

44（Plastic cover）

Steel / 22.17

PP+EPDM-TD20

/ 12.79

PP-LGF40 / 9.35

Body Design

BIW Weight（kg）

MaterialsPercent

（Audi A8）


BIW Cost

Design 4.1

ASF + Aluminum

cover

112

Al sheet 35% 39.2

RMB$5989(~USD$1000)

AL casting 35% 39.2


AHSS 4% 4.48

UHSS 4% 4.48

36（Aluminum cover）

Al sheet / 36

ASF + Al / Polymer Cover Cost Evaluation

Al Lightweight Body Cost Assessment


Lightweight Recommendation

Contents


Geely PEV Project



Challenges

• Example 1: Aluminium Engine Hood

Lightweight Design and Manufacturing Process

A l E ngine H ood Cost E veluation

Cost Com parison betw een A l and Steel E ngine H oods

A l E ngine H ood O neTim eInvestm ent

PerU nit CostSteel E ngine H ood O neTim e

Investm entPerU nit Cost

M at.Cost Int.Panel ¥ 190.00 IntPanel ¥ 87.00

E xt.Panel ¥ 210.00 E xtPanel ¥ 96.00

Stam p Cost Tooling（RM B$10K） ¥350.00 ¥ 17.50 Tooling（RM B$10K） ¥350.00 ¥ 17.50

Stem ping(RM B$) ¥ 0.80 Stem ping(RM B$) ¥ 0.80

Joining A dhesive (RM B$) ¥ 5.00 A dhesive (RM B$) ¥ 5.00

SPR (RM B$) ¥ 20.00 ¥ 1.00 SpotW elding (RM B$) ¥ 3.00

SPR Cost (RM B$) ¥ 15.00

Coating Filter E quip. ¥ 2.00 ¥ 0.10 N o Change

F. ¥ 1.00

Total (RMB) ¥440.40 Total (RMB) ¥209.30

Challenge

• Example 2: Aluminium Front Bumper

Lightweight Design and Manufacturing Process

Front Bumper Impact Result Comparison

Longitudinal Beam Collapse (mm)

LB Energy Absorption（%）

L/R B Pillar Lower End Accelleration(g)

L/R Door Frame Deformation (mm)

Orig.(Steel) 425.8 36.60 34.20/34.70 0.817/2.732

Proposal 1 558.1 30.56 37.61/40.58 1.450/3.333

Proposal 2 455.5 36.89 36.93/40.28 1.255/3.126

Proposal 3 471.2 37.19 35.07/42.28 0.811/2.981

Longitudinal Beam Collapse (mm)

LB Energy Absorption（%）

L/R B Pillar Lower End Accelleration(g)

L/R Door Frame Deformation (mm)

Orig.(Steel) 619.5 15.20 35.16/40.49 35.620/10.310

Proposal 1 641.1 12.84 41.35/43.58 56.484/12.337

Proposal 2 634.0 15.45 46.3/40.54 41.597/13.844

Proposal 3 658.6 16.02 42.05/41.94 40.410/6.900

Front Impact Results

40% Offset Impact Results

Challenge

吉利KCGEELY KC

安全Safety

环保Environmental Protection

轻量化Lightweight

Challenge

full aluminium body for pev - lbcg

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