Functional and Innovative Light Weight Concepts and ... · •Thickness 2,0mm Mini Paceman (R61) •Hotforming parts: whole B-Pillar •Indirect process with uncoated 22MnB5 •delivery

Functional and Innovative Light Weight Concepts

and Materials for HEVs October 10th, 2014

Schaffhausen, Swiss

C. Dietrich/B. Götzinger Lightweight advanced development–

MAGNA STEYR Engineering AG & Co KG

October 10th, 2014 C.Dietrich/B.Götzinger Disclosure or duplication without consent is prohibited 2

Content

MAGNA STEYR INTRODUCTION

AUTOMOTIVE CHALLENGES

SUMMARY – OUTLOOK

LIGHTWEIGHT BODY SOLUTIONS

GLOBAL MEGATRENDS


Content



SUMMARY – OUTLOOK


GLOBAL MEGATRENDS


MAGNA STEYR Introduction

Management Structure MAGNA Int.

Vince Galifi Chief Financial Officer

Jim Tobin Chief Marketing Officer, President Magna Asia

Jeff Palmer Chief Legal Officer

Tom Skudutis COO Magna Interiors, Exteriors, Seating, Mirrors, Closures and Cosma

Swamy Kotagiri Chief Technology Officer

Marc Neeb Chief Human Resources Officer

Guenther Apfalter President Magna Europe

Mike Sinnaeve VP Operational Improvement & Quality

Don Walker Chief Executive Officer

Joe Pittel

President

Albert Lidauer

President

Frank Seguin

President

John Farrell

President

Jake Hirsch

President

Guenther Apfalter

President

Mike Bisson

President

Joe Pittel

Acting President

MAGNA SEATING MAGNA EXTERIORS MAGNA INTERIORS MAGNA MIRRORS &

MAGNA CLOSURES COSMA INTERNATIONAL

MAGNA POWERTRAIN &

MAGNA ELECTRONICS MAGNA STEYR

Seating Exteriors Interiors Vision, Closures, Lighting,

Sealing & Roof Systems

Body & Chassis Powertrain & Electronics Vehicle Eng & Contract Mfg;

Fuel & Battery Systems



We offer …

Fuel systems and compressed-air tanks

Flexible solutions from niche to volume

production

Engineering services including

complete vehicle development

Vehicle Contract

Manufacturing

Fuel Systems

Battery Systems

Engineering

Innovative battery systems



Our specific Competences

DIFFERENT ARCHITECTURES

World class engineering and production with multi-OEM experience

Short time to market regarding to validated virtual development process

Cost efficient and flexible contract manufacturing of complete vehicle

MULTI-MATERIAL-MIX


Content



SUMMARY – OUTLOOK


GLOBAL MEGATRENDS


Global Megatrends

Following…

GLOBALISATION INDIVIDUALISM

DIGITAL LIFESTYLE IMPACT ON ENVIRONMENT

NEW MOBILITY CONCEPTS RAW MATERIAL SHORTAGE DEMOGRAPHIC CHANGE LIMITED FOSSIL FUELS

HEALTH AND WELLNESS URBANISATION / MEGACITIES

FASTEST GROWING MEGACITIES AND MIDDLEWEIGHTS

Megatrends with different regional characteristics are the drivers for scalable, modular and

global vehicle architectures.


Global Megatrends

MAGNA Innovation Pillars

CLEANER

Efficiency and

Sustainability

LIGHTER

Lightweight

Material and Science

SAFER

Active and Passive

Safety

SMARTER

Comfort, Convenience

and Connectivity


Content


LIGHTWEIGHT CHALLENGES

SUMMARY – OUTLOOK


GLOBAL MEGATRENDS


Automotive Challenges

Factors of Influence

• profit improvement

• sales targets

• new markets

• return on investments

• shareholder value

• reputation

• energy consumption

global/regional

• emission targets CO2, NOx

fleet consumption

• safety regulations

• salary and remuneration

• total energy balance

Car makers in the area of conflict between legislator demands and consumer needs.

Legislation

• individual mobility

• TCO

• sustainability

• performance

• driving dynamics

• comfort

• prestige

Consumer

OEM


Development of

new materials

Production

processes

Automation

Simulation

Quality

Increased performance

“Fun to drive” & Safety

Super Sports Vehicles

Decreased fuel consumption/CO2

Cost & Eco Efficiency

High Volume Vehicles

platform conformity material BIW concepts

lightweight solutions regarding all modules

utilization of secondary effects (downsizing)

CO2 life cycle assessment (well-to-wheel)

Driving dynamics, Stiffness

prestige, design

demonstrator of automotive innovations

crash performance

Innovative lightweight will be transfered from performance segment to high volume production.


Drivers & Challenges for Automotive Lightweighting



MAGNA STEYR Network Partners (extract)

Industry-Partner

Voest Alpine

Thyssen

Krupp

Fronius

AMAG

EADS

Evonik

Böllhoff

Wethje

Scientific-Partner

TU Dresden

TU Wien

TU Graz

MU Leoben

LKR

Fraun-hofer

DKI

TU München

OEM

BMW

Daimler

Volks-wagen

Toyota

Peugeot

Renault

Opel

Porsche

Lightweight realization presumes a widespread cooperation network.

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Content



SUMMARY – OUTLOOK


GLOBAL MEGATRENDS


Lightweight Body Solutions

Serial Project Aston Martin Rapide

• Manufacturing Engineering for 4-doors multi material body-in-white

• Integration of unique Aston Martin production technology at the site in short term

• Qualification program for employees to meet demands of multi material body concept

Aston Martin Rapide – Highlights:

Aluminum structure with material mix for panels



Serial Project Mercedes-Benz SLS AMG

• 100 % new development of two aluminum bodies - in minimum time to the

benchmark in terms of function and quality

• Installation of new production technologies at the site in short term

• Craftsmanship on a high level for ambitious customers

Mercedes-Benz SLS AMG – Highlights:

Aluminum body consists out of nearly 100% Aluminum


aluminum solution

reference structure

Super Sport Car

Development of a

competitive solution

compared to a state

of the art monocoque

composite solution

advanced performance

Volumes up to 5.000 jpy

Targets in comparison to reference structure:

increase torsional stiffness about 10 %

reduce weight of passenger cell about 20 %

comparable crash performance

reference cost + 80 €/kg

Reference properties:

driving dynamics, stiffness

weight of passenger cell

crash performance

production costs

Qualification for virtual development and production integration of composite structures.


R&D Project CLC – Composite Life Cell



R&D Project CLC – Composite Life Cell

Production technologies serial components

e.g. continuous processes

Serial Production Processes

Resin Transfer Molding (RTM)

Pultrusion

Inserts: Aluminum casting or milling

Efficient differential design concept for CFRP monocoque.

Aluminium rear structure

Aluminium front structure

CLC


Mini Countryman (R60) • Hotforming parts: upper B-Pillar

• Indirect process with uncoated

22MnB5

• delivery status (MSF): sandblasted

• Thickness: 1,8mm – 1,5mm

• Joining of B-Pillar: spot welding in

combination with structural

adhesive

Peugeot RCZ (T75) • Hotforming parts: upper A-Pillar,

reinforcement of firewall

• Direct Process with AlSi coated

22MnB5 (UsiBor)

• delivery status: AlSi coated

• Thickness 2,0mm

Mini Paceman (R61) • Hotforming parts: whole B-Pillar

• Indirect process with uncoated

22MnB5

• delivery status: sandblasted

• Thickness 1,6mm

Efficient differential design concept for CFRP monocoque.


Presshardened Steel



R&D Project CULT – Target Achievement Leverages

Drivetrain

Increase in efficiency

Roll resistance

Aero-dynamik

Lightweight Design

Lightweight design will be the sifgnificant basis for the maximum potential on drivetrain side.


ca. -80kg

• Integration of functions (cancellation of parts)

ca. -100kg

• New materials (selective usage of lightweight materials)

ca. -120kg

• Downsizing (& use of secondary effects)


R&D Project CULT – Holistic Lightweight Concept

Base 900kg

engine: 660 cm³ instead of 1l

Target weight 600kg

Integrated fuel door

Multimaterial body

Different approaches

Holistic lightweight concept enables weight reduction up to 300kg.



R&D Project CULT – Product and Production Concept

Multi-material design requires/enables new manufacturing concepts.

Aluminium body structure (steel B-pillar)

Composite body panels (organo-sheet)

CFC Sandwich floor

Cimera firewall (steel sandwich)

Thermoplastic fender

GFC-Honeycomb-core roof

Joining techniques:

• CMT welding ~ 14m

• Punch-riveting ~ 778#

• FDS ~ 465#

• Bonding ~ 85m

Assembly-process:

• Bodyshop: Assembly of the metallic parts

• Paintshop: E-coat process, paint process

• Assemblyline: Floor, Firewall, roof etc.



The right Joining Solutions in the right Place

Self Pierce

Riveting Flow Drill

Screwing

Blind-

Riveting

High Speed

Tacking Bonding

Screwing

Gas-Shield

Welding Punch

Riveting

Friction

Element

Welding

Friction Stir

Welding Clinching

exception:

no spot joint

Production Engineering

average process time

certified material lab design for manufacturing

worker qualification

supplier network

Lieferantenlandkarte (EU)

18.10.2012 Author: Coreteam Aluminium Disclosure or duplication without consent is prohibited 26

LAND TECHNOLOGIEN

Österreich

Deutschland

Italien

Ungarn

Slowakei

Tschechien

Slowenien

Niederlande

Irland

Blechumformung

Profile

Gussteile

optimized simulation methods

design and material standards

21.09.2012 B. Kastreuz / Magna Steyr 15Disclosure or duplication without consent is prohibited

Joined Car Body

FE-Model

Automatically meshed

components

Connector lines

MPC-

Equations

Automated in Connector

Structure Elements

Mesh-independent

connectors

Mesh-independent joining techniques

Dominant flange deformation

Fatigue life estimation for joining

techniques based on parameter models

- detailed evaluations

- optimization

Spot weld

Self-piercing

rivet

Damage distribution

Seam weld

Seam weld endRobscan Bonding

Resistance

Spot Welding


Content



SUMMARY – OUTLOOK


GLOBAL MEGATRENDS


Summary – Outlook

Holistic Lightweight Concept

Low Volume [~5.000 cars p.a.]

sports and luxury cars

Mid Volume [~25.000 cars p.a.]

niche vehicles & derivatives

High Volume [>>50.000 cars p.a.]

platform-based vehicles

material trend: composite/aluminum material trend: multi-material, hybrid material trend: steel/aluminum

Rolls-Royce Phantom VW Golf VII Daimler BR205 BMW 6er BMW i8 Porsche 991

aluminum

steel AHSS

steel HSS

compositealuminumsteel AHSS

steel AHSS

steel HSS

compositealuminumsteel AHSS

composite

aluminum

steel AHSS

aluminum

steel AHSS

steel HSS

Engineering

• design rules for structural bonding

• validated simulation of composites

• design rules for multi-material BIW

• validated simulation of joints

• increased application of AHSS

• virtual methods for optimization

Contract Manufacturing

• alternative production concepts

• composite-oriented body shop

• high-flexible hybrid joining cells

• quality concepts for hybrid design

• platform-oriented production lines

• inline-capable quality control

Focus on EU market, BIW structure


Auflistung aller prägnanten Vorteils-Argumente


THANK YOU

for Your Attention!

Documents

Functional and Innovative Light Weight Concepts and ... · •Thickness 2,0mm Mini Paceman (R61) •Hotforming parts: whole B-Pillar •Indirect process with uncoated 22MnB5 •delivery