Lightweight Design By Functional Integration Using Magnesium Castings
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1 Lightweight Design By Functional Integration Using Magnesium Castings 2012 China Automotive Lightweight Technology Forum Beijing, September 10 th +11 th Elmar Beeh, Oliver Deisser, Horst E. Friedrich, Gundolf Kopp
2 Chart 2 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Lightweight Design By Functional Integration Using Magnesium Castings DLR & Institute of Vehicle Concepts Challenges of Lightweight Design DLR Front Structure SLC Front Structure Summary Forecast on a planned Magnesium project (LISa-EV)
3 Chart 3 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Locations and employees DLR & Institute of 7000 employees across Transport Research Stade Hamburg 32 institutes and facilities at Neustrelitz Bremen 16 sites. Trauen Offices in Brussels, Berlin Braunschweig Paris and Washington. DLR & Institute of Transportation Systems Goettingen Research Areas: Aeronautics Space Research and Technology Transport Energy Space Administration Project Management Agency DLR & Institute of Vehicle Concepts Juelich Cologne Bonn Lampoldshausen Stuttgart Augsburg Oberpfaffenhofen Weilheim
4 Chart 4 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Vision CO 2 -neutral vehicle Increase of energy efficiency Key aspects of activity Reduction of driving resistances synthesis
5 Chart 5 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > What are the Challenges within Lightweight Design? From technological point of view lightweight design is not a big problem Source: BMW, McLaren Mercedes, VW, Audi, Loremo
6 Chart 6 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > What are the Challenges within Lightweight Design? / kg space aircraft 500 train 50 5 automotive 1/a 10/a 100/a /day units Costs and productivity are crucial parameters for the application of lightweight design solutions
7 Chart 7 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Lightweight design strategies Step 1 Materials Step 2 Concept Step 2.1 Step 2.2 Law Customer and Market CO2-Strategy Package Design Integration Modularisation Technologies Materials Surfaces Processes Requirements, Conditions and Standards Shape Geometry Sources: Haldenwanger (1997) DLR (2007)
8 Chart 8 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Topology Optimisation
![Structure Parts Part name german Part name [mm] Material Total Weight [kg] PID Front 1.4.4 2 Rahmen Seite (Radhaus VA) FRAME, DASH PANEL 1,20 HX 220 PD + Z 2,079 (1)19000 1.1.2 2 Längsträger Deckelteil vorn SIDE MEMBER 1,60 HX 300 LAD + Z 4,163 (10)5000 1.](/docs-images/75/72582269/images/9-1.jpg "2 2 Radhaus vorn WHEEL HOUSING,FR 1,10 HX 220 PD + Z 1,886 (1)10000 1.2 2 Längsträger oben innen SIDE MEMBER INNER UPPER 1,00 HX 220 PD + Z 1,242 (1)12000 Verstärkung REINF.SUSPENSION STRUT 1.")
9 Chart 9 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Integration of parts and functions A5-SLC Part List Steel reference data from Part List: Weight: ~ 8 kg Part Costs: ~ 25 A5 Reference No. of Thickness Pos. Structure Parts Part name german Part name [mm] Material Total Weight [kg] PID Front Rahmen Seite (Radhaus VA) FRAME, DASH PANEL 1,20 HX 220 PD + Z 2,079 (1) Längsträger Deckelteil vorn SIDE MEMBER 1,60 HX 300 LAD + Z 4,163 (10) Radhaus vorn WHEEL HOUSING,FR 1,10 HX 220 PD + Z 1,886 (1) Längsträger oben innen SIDE MEMBER INNER UPPER 1,00 HX 220 PD + Z 1,242 (1)12000 Verstärkung REINF.SUSPENSION STRUT ,50 HX 220 PD + Z 1,895 (1)11100 Federbeinaufnahme MOUNTING Federbeinaufnahme vorn SUSPENSION STRUT 2,00 HX 220 PD + Z 3,231 ( MOUNTING Adapterteil LTR oben (inkl. ADAPTER PART 1,75 HX 220 PD + Z 0,831 (1)13000 Schottteil) Schliessteil Wasserkasten END PLATE 0,70 HX 220 PD + Z 0,335 (1) Wasserkasten Vorderwand WATER BOX 0,50 HX 220 PD + Z 0, Stirnwand CROSS PANEL 1,00 / 2,00 HX 220 PD + Z 6, Stegteil Wasserkasten WEB PART WATER BOX 1,00 HX 220 PD + Z 0, Wasserkasten Unterteil WATER BOX LOWER 1,00 HX 220 PD + Z 0, Querträger Stinwand CROSS MEMBER BULKHEAD 1,00 HX 220 PD + Z 2, Verstärkung Querträger Stirnwand REINF. CROSS MEMBER 1,00 HX 220 PD + Z 2, Rahmen Montageplatte Stirnwand oben FRAME,MOUNTING PLATE 2,00 HX 220 PD + Z 4, Säule A innen unten Unterteil PILLAR A,LOWER INNER 1,75 HX 260 LAD + Z 2,033 (1) A-Säule innen unten Oberteil PILLAR A,UPPER INNER 1,50 HX 300 LAD + Z 2,562 (1) Verbindungsstück CONNECTING PIECE 2,00 HX 220 PD + Z 3,255 (1) Haltebock Batterie vorn MOUNTING REINFORCEMENT BATTERY (FRONT) 2,50 HX 220 PD + Z 0, Haltebock Getriebelager links RETAINER BATTERY 2,00 HX 220 PD + Z 0,
10 Chart 10 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Cost Estimation of Mg Part Presuppositions: Possible Weight saving: > 40 % Costs per Kilogramm Mg part weight: ~ 10 /kg Steel reference: ~ 8 kg ~ 25 Mg (estimated): ~ 4,8 kg ~ 48 Lightweight costs: ~ 7,2 /kg saved
11 Chart 11 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Cost Estimation of Mg Part Steel reference: ~ 8 kg ~ 25 Mg (estimated): ~ 4,8 kg ~ 48 Lightweight costs: ~ 7,2 /kg saved Steel reference data from Part List with more parts integrated: Weight: ~ 11 kg Part Costs: ~ 45
12 Chart 12 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Cost Estimation of Mg Part Steel reference: ~ 11 kg ~ 45 Mg (estimated): ~ 6 kg ~ 60 Lightweight costs: ~ 3 /kg saved With this concept we have the chance to meet the cost targets of automotive industrie
13 Chart 13 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Conceptual Design New design, with integration of the suspension pick-up in the a-pillar Force flow without detour over the longitudinal beam High lightweight potential
14 Chart 14 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > DLR Front Structure Detailed Engineering Design: CAD-Design, final weight 5kg Optimisation of the part topology Wall thickness optimisation Static and dynamic simulation Threadforming Screw Aluminum Spacer Bracket Washer h Magnesium Blind Boss Corrosion protection: Best applicability of the concept, if sill, window-frame and front crossmember is made from aluminium Proper design Joining solutions like in serial production
15 Chart 15 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > SLC Front Structure SuperLightCar Project Objective: - weight reduction versus reference compact class body in white (BIW) at minimal additional costs - weight reduction: 85kg ( 30%) - lightweight costs (parts costs): 5 /kg Realisation: - complete CAD-design for BIW - validation of structural performance (crash, static, etc.) - description of joining technologies and production processes - Life cycle analysis (LCA) for multi-material vehicle concepts - assessment of different body concepts Coordination: Volkswagen Consortium: 37 partners
16 Chart 16 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > SLC Front Structure SuperLightCar Project Phases TP1 Concept development Detailed SLC concept 1) Steel intensive 2) Multi-material mix, economical (ULBC) 3) Multi-material mix, weight optimized (SLBC) < 2,5 /kg < 5 /kg < 10 /kg TP2 Preliminary SLC concepts Material and production technologies Technology screening Forming joining technology Production planning TP4 Assembly SLC BIW Prototype TP3 Analysis & simulation Life Cycle Analysis (LCA) Cost evaluation Virtual and physical testing
17 Chart 17 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > SLC Front Structure Reference Structure
18 Chart 18 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > SLC Front Structure Construction Method and Material part list Design topology optimization Unibody Spaceframe Sheet metal parts Profiles Combination Casting Parts Materials Steel, Aluminium, Magnesium, FRP,
19 Chart 19 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > SLC Front Structure SuperLightCar Project Phases Materials Aluminium sheet Aluminium cast Aluminium extrusion Steel Hot-formed steel Magnesium sheet Magnesium diecasting Glasfibre thermoplastic 12 steel stamping parts integrated Part weight 2,8 kg Weight benefit 4,7 kg (63%) Material: EN-AW 5182 or 6014 Gauge: 3,0/3,8/2,6 mm TWB Weight: 4,3 kg Material: Gauge: Weight: AM50 2,0-2,5-3,0-4,0 mm 2,9 kg + 2,8 kg
20 Chart 20 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > SLC Front Structure Crash Simulation Comparison Reference Structure vs. SLC Refer. 100mm 56g SLC 51mm 55g
21 Chart 21 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Summary Highly integrated magnesium castings offer weight benefits up to 60 % With the right strategy Mg concepts can offer very cost attractive lightweight solutions The chances for success of Mg concepts can be foreseen with the methodology shown in the two examples of the presentation
22 Chart 22 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Forecast on a planned Magnesium project Light metal Intensive Safe-Electric Vehicle (LISa-EV) Motivation Reduction of the energy consumption of (Chinese) electric vehicles (EV) Increasing range of EV s Increasing the use of Chinese magnesium resources Reduction of CO 2 -emissions of the Chinese light metal production chain Strengthening collaboration between German and Chinese industry Content Weight reduction of the body of an Chinese reference EV > 40% Reduction of energy consumption of EV > 25% Reduction of energy consumption and emissions of the magnesium production route Keeping lightweight design costs significant lower than battery costs Body completed with components of the reference car to an drivable technology demonstrator
23 Chart 23 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Forecast on a planned Magnesium project Light metal Intensive Safe-Electric Vehicle (LISa-EV) Mg solutions for today s cars Challenges: Corrosion protection Joining technology Thermal expansion Techn. approach for LISa-EV Intensive use of magnesium with local steel and aluminium reinforcements with new strategies for todays challenges
24 Chart 24 > Lightweight Design > O.Deisser LWD-Functional-Integration-Mg_p.pptx > Ideas that move!
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