Carbon Core &amp;ndash; die neue BMW 7er Karosserie

Ahlers, Michael

doi:10.1007/978-3-658-14144-8_9

Cited by 8 publications

(5 citation statements)

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“…For BEVs, a 100kg weight reduction may increase the driving range by 4% in urban traffic [3]. To realize economically acceptable lightweight designs, vehicle body-inwhite (BIW) structures are increasingly being built using multi-material designs consisting of steel, aluminum (Al), magnesium, and fiber-reinforced plastic (FRP) [4,5].…”

Section: Introductionmentioning

confidence: 99%

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Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Fang¹,

Kloska²,

Hajdarevic³

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Fiber-reinforced plastics (FRPs) are increasingly being used to reinforce steel or aluminum (Al) automotive structure components. Currently, these multi-material applications are realized via three-stage manufacturing, which require the corresponding costs. Thus, a new hybrid forming technology has been developed and will be presented here. It is based on the principle of the hydro-mechanical sheet metal-forming technique and uses a heated thermoplastic FRP material (up to 280°C) in a half melting state as the pressure media to form steel or aluminum sheets. Since the sheet metals are pre-coated with an adhesion promoter, the FRPs are also joined with the sheet metal during this hybrid forming process. In this work, the die and especially the sealing concepts for hybrid forming will be introduced based on different part geometries. The formability of the sheet metals (Nakajima test) at different temperatures up to 280°C, for each two steel and Al alloys, will be presented. The hybrid formed parts were analyzed using optical method and section analysis. Good forming results were confirmed for both sheet metal and FRPs. A vehicle chassis component was successfully hybrid formed using CP-W800 steel and FRP, and a body component was produced using an Al5182 alloy and an FRP.

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Section: Introductionmentioning

confidence: 99%

“…The multi-material designs in [4,5] were both realized using the so-called "post molding assembly" (PMA) and "in-mold assembly" (IMA) approaches. In the PMA process, metal and FRP components are initially manufactured separately and then joined together in a third assembly step.…”

Section: Introductionmentioning

confidence: 99%

Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Fang¹,

Kloska²,

Hajdarevic³

2022

IOP Conf. Ser.: Mater. Sci. Eng.

View full text Add to dashboard Cite

show abstract

Section: Introductionmentioning

confidence: 99%

“…Lightweight design is one of the most important measures to reduce fuel consumption of vehicles using internal combustion engines or extending the driving range of pure battery driven vehicles (BEVs) [1][2][3]. To realize economically acceptable lightweight designs, vehicle body in white (BIW) structures are increasingly being built using multi-material designs, consisting of steel, aluminum (Al), magnesium, and fiber reinforced plastic (FRP) [4,5]. However, all the wheel-guiding components in the chassis of series-production vehicles are still manufactured from steel or Al.…”

Section: Introductionmentioning

confidence: 99%

Hybrid Forming - A Method for Simultaneous Forming of High Strength Metal Sheet and Long Fiber Reinforced Plastic

Fang

Kloska

Heidrich

2022

KEM

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Fiber reinforced plastics (FRPs) are increasingly being used to reinforce the steel or aluminum automotive structure components. Currently, these multi-material applications are realized in general by a multi-stage manufacturing with considerable cost increase. To avoid this, a new hybrid forming method has been proposed and developed. It uses the half liquid FRP as a pressure media to hydro-form the sheet metals, form the reinforcement ribs of FRPs, and create the bonding between metal sheet and FRP in the same time and process step. In this work, the die sealing concepts for two test geometries could be successfully developed. The hybrid forming parameters (Temperature, pressure, speed etc.) are in a reasonable range and can be accepted by the industry. It could be approved that high strength steels with up to 800 MPa tensile strength could be hybrid formed successfully together with a LFT PA6 GF40 for a real car component. 20% weight reduction could be achieved.

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“…In the field of car manufacturing a variety of components seem to be suitable for the approach. With the braided carbon fiber reinforced roof frame reinforcement of the current 7-series, the BMW Group has proven that the process is applicable for high-volume production and together with an efficient injection process such as resin transfer molding (RTM), is competitive to the otherwise applied steel and aluminum designs [1]. The possibilities to realize customized laminate properties for braided components are limited as the braid type (e. g. biaxial or triaxial, hence the number of thread systems in the textile, see Fig.…”

Section: Introductionmentioning

confidence: 99%

Analysis of a Process Approach for Production of Triaxial Braids with Locally Customized Filler Yarn Count

Eschler

Hüls

Zaremba

et al. 2019

KEM

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In order to enhance lightweight potential and fabrication efficiency of structural parts from carbon fiber-reinforced plastics, the approach of locally tailored component properties has proven effective. For braided hollow profiles, however, technical possibilities to achieve process integrated adaption of a components’ mechanical properties are limited. Therefore, a novel braiding process approach for cycle-time-neutral adjustment of a triaxial braids filler yarn count is examined and its advantages for component design are illustrated. The main objective of this study is to evaluate the approaches applicability with regard to process stability and disturbance of product quality. Two consecutive test series are carried out to identify the most influential process variables and to link the variation of these variables with multiple criteria of process quality. A clear dependency between quality and braid angle, braid yarn tension as well as the number of filler yarns the approach is applied on is derived. On that basis a set of process variables for faultless application of the concept is pointed out.

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Carbon Core – die neue BMW 7er Karosserie

Cited by 8 publications

References 0 publications

Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Die Concepts and formability for simultaneous forming of sheet metals and FRPs

Hybrid Forming - A Method for Simultaneous Forming of High Strength Metal Sheet and Long Fiber Reinforced Plastic

Analysis of a Process Approach for Production of Triaxial Braids with Locally Customized Filler Yarn Count

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