simply light! – new ways for the realization of future ... zur teleconf 110119 v2_en.pdf ·...

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Simply light! – New ways for the realization offuture technologies and business models for

innovative lightweight concepts in automotive engineering*Online Meeting - "Sum of the Parts: Light Weight Materials in Automobiles"

AGRION Internet Conference, January,19th, 2011Dr.- Ing. Peter Klose, MBtech Consulting GmbH, Sindelfingen

* 10th International Symposium Stuttgart Automobile- und Engine technologyHaus der Wirtschaft, March 17th, 2010 (Excerp)

2006-XX-XX 22

MBtech provides engineering and consulting services for the automotive industry worldwide

2

2700 employees worldwide

Turnover: € 320 million in 2010

GLOBAL PRESENCE

POSITIONING

Close relationship to customers on three continents

FACTS & FIGURESDie MBtech Group

The MBtech Group is a leading global provider for automotive engineering and consulting services

MBtech offers comprehensive expertise along the entire automotive product value creation process and product life cycle

MBtech is a business group within the Daimler AG

High level of customer and service orientation- Interdisciplinary project teams- Close partnership with suppliers, customers and

cooperation partners- Outstandingly competent, professional and

committed employees

1 MBtech Group overview

10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik

2006-XX-XX 33

MBtech services cover the entire range of automotive engineering and consulting services

Class A and technical styling

Body developmentBody-in-whiteExteriorInterior

Chassis development

Full vehicle integrationDesignNumeric calculationSimulation

Full vehicle testing and validation

Production Engineering

Methods, training, support

Combining design, functionality and economy

Management Consulting

Technology & Innovation Consulting

Process Consulting

Program & Project Consulting

Business Academy

Technology and process expertise for long-term success Motor concepts

Engine variants

Exhaust gas after-treatment

Turbocharging systems

Combustion process development

Development of injection systems

Development and operating test fields

In-vehicle powertraintesting

Planning and design of production facilities and processes

Innovative solutions for the entire powertrain

Systems engineering

Software engineering

Test Engineering

Validation & compliance

EMC Services

Reliable, high-performance customized E/E solutions

consulting vehicle engineering powertrain solutions electronics solutions

3

1 MBtech Group overview


DVM day 2008Dr. P. Klose, MBtech Consulting 4

Light-weight design is more than the use of light materials

Light-weight function

Acoustics, smart structuresVibration abs.WarmthCorrosion/ TribologyMechatronics, E/ET

Light-weight materialsHigh-strength steelsLight metals Al, Mg, TiSMC, composites (GF/CFK)Micro-disperse, nano-materialsFunctional paints/coatingsHybrid composites (Metal/plastic)Anisotropic materials (positioned

solidified)

Light-weight constructionLaser welding, laser solderingTailored BlanksRoller profilesMAG welding

15

24

3

Light-weight molding

Red. mounting offsetOpt. mountingNode conceptsCasting proceduresHollow structuresHydroforming

Light-weight design concept

Broader application spectrumsType-independent reinforcementDigital material development and validationModularization

The optimal light-weight design potentials can only be realized through an integrated approach

Efficient material systems, processing

Innovative joining technologies

Reducing complexity

Function integration

Modular construction

Flexible manufacturing concepts

Influencing factors

Source: MBC, Dr. Klose 2008

2 Light-weight design concepts, Trends (Overview)

5

Innovations in the automotive industry are becoming more com-plex and need to be addressed increasingly cross-functionalNetworked Innovation Fields : fast processes, lightweight structures, efficient drives

Fast processesLightweight structuresEfficient drives

Innovation topics "Energy-efficient vehicle" (selection)

Source: MBtech Group

Fast implementation

Consistent linking physical-digitaltoolsRapid-technologies ready for serailproductionConsistent, linked simulation tools

Lightweight design

Intelligent, multi-functionalStructures

Hybrid Material SystemsEconomic production processes

Propulsion technology Drive technology - Optimization Combustion- Optimization mechanical losses- Electric Cars / HybridInfrastructure technology


3 Trends in technology

666

New materials – point of departure for each automotive lightweight design applicationThe potential use of materials available is determined by their functions(e.g. crash, lightweight design), recyclability, costs, surface quality, joining technology and theavailability of simulation data (static/ dynamic)Steel [1] Aluminium [2] Magnesium [3]

Steel-Al hybrid [2] Plastic-Al hybrid [2] Plastics/composites [4]

Source: [1] Opel GmbH [2] Audi AG [3] Volkswagen AG [4] Daimler AG 10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik


7

2010 ?

Use of tailored blanks in volume series

Thin-gauge high-strength blanks

1982

CitroenTraction Avant

1934

Large presses for body panels

Lancia Lambda

1923

100% galvanizedsteel car body

1975

First assembly line produced Ford Model T

1910

Pressed steel frame(Mercedes)

1902

ULSA-x and NSB studies

Milestones of steel car body technology – “design“ competition between material development and process technology

Source: By TKS 2006

1986

1994 - today


DVM day 2008Dr. P. Klose, MBtech Consulting 8

TrendsDiverse application spectrum of modern steels

Tensile strength Rm [ N/mm² ]

0

Stra

in a

t fai

lure

A80

[ % ]

Al alloy

Mg alloy

1200200

40

20

0 400 600 800 1000 1400

60

Stainless steels

Advanced Steels

X-IP

Higher expansion with increased stability

Expanded product application spectrum in the body and chassis areas

Increased crash-safety through the work-hardening effect

Personal security, ballistic protection

Broader range of operating temperatures

Easy processing

Proven surface protection

Established joining procedures

Thin metal structures

Use of new tool technologies, materials, resources, cutting materials

Develop cooled forming tools with controlled blank holders

TemperatureSurface/interfaces

New material concepts offer a unique range of applications and cost/benefit ratiosOverview: High-strength steel alloy systems /alternative material groups

Conventionalsteels

Source: MBCauf basis TKS data Material symposium Vehicle technology, Stuttgart 2007

CeramicsTitanium

3 Light-weight design concepts, Trends (Overview)

9

The choice of lightweight-appropriate joining technologies/hybrid technologies has to be matched to the material systems (excerpt)

Joining costs/ complexity

Joiningquality

MiG brazing

Resistance spot welding

Clinching

CMT

US-friction-welding Al+ST

Self Piercing Rivets

Bonding + boltsLaser welding

Friction steer-welding

Flowdrill

Hybrid Joining

Bonding/NT-diffusion brazing

Low High

Low/No

adhesivebond

High/Full

adhesivebond

Meeting Akzo Elring Greiz 101018, Dr. Klose MBtech


10

New innovative surface protection processes will revolutionize conventional pre-treatment and paint technology

Al

Zn Mg

Impr

oved

corro

sion/w

hite r

ust

resis

tance

Hybrid

desig

n with

stee

l/ Al

Improved white rust resistancePassivation of zinc layers

(Mg-compatible coatings on steel)

White rust resistance (Mg-

compatible coatings on steel)

Deposition of pure metals duringthe gaseous phase – Al, Al/Mg, Zn, B, Fe– as pure metal or– graded layers – at normal pressure

Application of combined process technologies– E.g. galvanizing– Diffusion processes– Heat treatment processes

Unaffected by the part geometry/contourEasy integration (regardless of direction – horizontal/ vertical)Easy loading/unloadingCan be combined with variousafter treatmentsFree of Cr and Cr-VI

Benefits

Technology of the MO CVD process(Metallorganic Chemical VapourDeposition)

Standard parts

SheetsExhaust manifold

Source: InnCoa GmbH 2008

Business case- Innovative coating system

1111

Lightweight by function integration: micor-disperse isolation in the chassis saves weight, constructed space and costs

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Initial situation

Chassis (tailored blank) 18,5 kgAcoustics insulation (heavy mats) 3,5 kgHeat insulation (shielding plates) 1,3 kg

Integrated acoustics and heat insulation

Double walled transmission tunnel with micro-disperse layerDrop of acoustics insulation and shielding platesShortening of assembly processWeight reduction -1.3 kgIncrease of rigidity through sandwich construction

Isolation of chassis – Series stand BR212 Function integrated chassis in sandwich construction (concept draft)

Sandwich concept offers a weight reduction of 4.8 kg with lowered costs and drop of 10 parts


Business case- Innovative heat insulation system

1212

The timely change of the maturity degree of different technologies will determine the future body in white design

Application

Pilot application

Pilot manufacturing

Demonstrators

Feasibility studies

Material characterizationBasics

Maturity degree

Research Development Production

AdvancedMg-alloys

Ti-alloys

Highly firm structure-CFK

StandardMg-alloys

Optimized steel lightweight

Nano-mat., new surface technologies

Smart structures

TiAl

Metal- and ceramic-sponges

Metal matrix composites

Ceramic application(e.g. engine components,

surface technologies)

Al-alloys

Meeting Akzo Elring Greiz 101018, Dr. Klose MBtech


13

The realization of innovative vehicle concepts requires a parallel development of agile and flexible organization formsBusiness case: platform configuration of OEM with respective complexity mgmt.

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Parallel organization development forthe realization of new vehicle constructions

Material– Aluminum– Steel– Plastic– Hybrid– …

System– Shell construction– Integral carrier of transmission– Structure carrier of transmission– Quantity– …

Geometry conditions– Product– Tool design– Production form– Production technology– Inclusion and clamping concept– …

Processes– Added value– Material flow– Capacity– Flexibility– Suppliers– …

Product requirements– Design– Performance specifications– Law requirements– Available space– Force progression curve– …

4 Towards realization of innovative lightweight concepts

Joining technologies– Welding– Riveting– Adherence– Clinching– …


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Lightweight in vehicle development – the entrepreneurial dimension

Styling

Processvalidation

Al PVDZn CVD

Material/surface

Concept Construction

Modules

Test loops

SimulationTechnology/electric/

electronic

PrototypesDigital plantEquipmentProduction Tools

5 Outlook

Lightweight in the car is not only a question of the material or the construction way. If lightweight has to be carried out effectively and efficiently the whole product development process has to be aligned with it – a management of competences together with system partners is necessary


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