FlexBody – ROADSHOW 2012 – LIGHTWEIGHT TECHNOLOGY
SMART APPLICATION KIT FOR LIGHTWEIGHT
MULTI-MATERIAL BODY STRUCTURES
Speaker:
October 2012
Dipl.-Ing. Gerhard von Kulmiz / Imperia GmbH
Agenda
page 2
Partners / Consortium
Motivation for Body Structure Kit
Methodology
Application & Validation Projects
Structural Validation – Crash
Material Concept
Cost Calculations for Low Volume Cars
Volume Dependent Manufacturing
Industry and Research Consortium
page 3
INDUSTRY
RESEARCH
PARTNERS
PARTNERS
Motivation for a Smart, Lightweight Body-Structure-Kit
page 4
Satisfies the small series homologation needs (< 1.000 car/year)
Quick to market
Low investment
Limited engineering resources (high knowledge base)
Dedicated and clear attributes management
Methodology - Geometrical and production-technological intelligence
Manufacturing
Geometry
Knowledge Base
Structural
page 5
Topology
Profiles
Joints
Body Structure Kit
Methodology – Development process
page 6
Vehicle Base Information
Attribute Configurator
…
H
mv
Vehicle Base
Information
Attributes
Configurator
Global Deformation
& Stiffness Targets
Topology Configurator
Topology Configurator
d
Section & Beam Configurator
Component Targets
Options
Choice
Section & Beam Configurator
b
Joint Configurator
Joint Configurator
- Material Choice
Validation (virtuel)
- Mfg. Restrictions
- CAD Knowledge Base
Final FEM-Validation
- Stiffness
- Crash
Validation Vehicles
page 7
Lampo 3 (Concept)
“Central Pipe Integrated Frame”
Source: www.protoscar.com
ec2go (car sharing)
ego (Golf Caddy)
“Body Integrated Frame”
Structural intelligence – Example Crash
page 8
• frontcrash
• sidecrash
• roofcrash
• pole side
• pole front
Final Evaluation
using FEM
• Low speed
Materialmix
page 9
Aluminium
HS Aluminium
Stainless Steel
CrNi
HS-Steel(DP1000)
Steel
CFRP
GFRP
„The right material at the right place!“
Combinations of different materials are possible
Focused on lightweight design and functional requirements
Combination of various cross sections due to modular construction system
Body integrated frame for maximum battery protection
Material Concept: Joints
page 10
A
C
A
A
B
A
B
B
A = Aluminium
B = Steel-Aluminium-Hybrid
C = Titanium
Example of cost calculation for low volume cars
page 11
Specification
Material supply
Topology
Manufacturing
Gesamtkosten
3-armig
4-armig
3-armig
4-armig
Durchschnittskosten
3-arms
4-arms
Milling
lost-wax-casting
Milling lost-wax-casting
100
200
LP-sand-casting
low pressure-sand-casting
300
400
Alu
Alu
500 No. Joints
Example of manufacturing concept: Joining Technology
page 12
New process: Injection bonding
Motivation:
- tolerance friendly
- no welding distortion
- material combinations are possible
Example: Injection Bonding
page 13
1.) Sealing inside via adhesive
2.) Sealing outside via adhesive
3.) Injection & leak test
Adhesive seal o.K.
Volume dependent manufacturing technology
page 14
Investment
jig / fixture technology
partly automated
jig / fixture technology
manuel
jig / fixture technology
burn-out-templates
Volume
Example: e-car project
page 15
Summary
page 16
FlexBody concept is giving the chance to realize
low volume niche vehicles projects.
Body integrated frame for maximum battery protection
Injection bonding for “cold” body manufacturing and
possible use of different materials.
Reduced engineering efforts due to high degree of
standardization and parametric design
Hybrid casting technology to combine different materials
and reinforce critical areas
Volume dependent manufacturing technology
THANK YOU FOR YOUR ATTENTION
Contact: Gerhard von Kulmiz, Imperia GmbH
Soerser Weg 9, 52070 Aachen, Germany
Phone: ++49 (0) 241 60833-0
October 2012
www.flexbody.net